The present disclosure relates generally to self-supporting vacuum plumbing assemblies including accumulators that can be used to mount one or more plumbing fixtures in a desired location, as well as related systems and methods, all without requiring use of an external or peripheral frame to secure together the components of the assemblies that must be attached to the accumulators during transportation and handling, and/or during or after installation of the assemblies. The assemblies can be made self-supporting, for example, via use of rigid connections between the conduits (risers) and the accumulators within such systems, thereby eliminating the need for an external support frame, so that the combined construction is sufficiently rigid after manufacturing that the assemblies can be transported and installed in such form. The self-supporting construction of the assemblies has particular utility within modular and/or premanufactured wall systems, where only a narrow space may be available between wall surfaces, but the assemblies have utility within any type of interior or exterior wall or compartment of a building, or anywhere inside or outside of a building a plumbing connection and fixture are desired.
Various types of plumbing drainage systems are used to direct waste from one or more sources to a common collection point. For example, gravity feed systems are commonly used in residential and commercial buildings. In a gravity feed system, gravity provides the motive force to move the waste from the source(s) to the collection point. Because gravity is the main motive force, the pipes between the source(s) and the collection point must slope down toward the collection point to maintain the desired flow. The requirement that the pipes slope also requires careful design to assure that the pipes are properly located. For residential and commercial buildings where floors are formed of concrete slabs, particularly those with steel reinforced slabs, installation and reconfiguring of supply and draining piping can be difficult and/or limited by the slab structures.
Drainage systems using suction to draw waste from sources have been introduced to offer an alternative to gravity systems. These systems are commonly called vacuum plumbing systems, vacuum-assist wastewater systems, or the like. Such systems use a combination of gravity and suction (i.e., a pressure less than ambient atmosphere, but not strictly speaking vacuum per se) to draw waste from the source(s) to a collection point. Because the main motive force is suction rather than gravity, the orientation of the pipes need not be downwardly sloped as in gravity feed systems.
Often, plumbing and electrical connections used to connect plumbing fixtures to vacuum-assist plumbing systems are overhead (i.e., within or above ceilings, below overhead flooring, etc.). In such case, risers within the walls extend from the plumbing fixtures up to such connections to facilitate and protect liquid and electrical connections. While such systems work well, installation requires use of multiple professionals and tradespersons (i.e., MEP engineers or designers, plumbers, electricians, framers, drywallers, etc.) to design, assemble from many parts, and custom install each fixture and the riser connections in such systems. If designs are changed during construction or buildings are to be reconfigured later, an added level of complexity and cost is involved.
Fitting such systems within a wall can also be a challenge due to the minimal space available within typical site-built walls and in particular modular walls, which are often thinner in profile. Use of any external or peripheral supports, framing, etc., on such systems, including those disclosed in U.S. patent application Ser. No. 17/364,403, filed Jun. 30, 2021, necessarily adds bulk and/or weight, thereby interfering with use of such systems in walls, and complicates the assembly, handling, transport and/or installation of such systems. Therefore, a cost-effective, simplified, and effective self-supporting vacuum plumbing assembly for attaching a plumbing fixture to a vacuum-assist waste removal system and/or a water supply system, an installed assembly with plumbing fixture(s), a vacuum plumbing system, and method of installation and use, addressing one or more drawbacks of existing systems, or other needs, would be welcome.
According to certain aspects of the disclosure, a self-supporting vacuum plumbing assembly for attaching a plumbing fixture to a vacuum-assist waste removal system may include an accumulator associated with the plumbing fixture for receiving and holding wastewater from the plumbing fixture, a wastewater inlet opening being defined in the accumulator for receiving the wastewater from the plumbing fixture. A wastewater outlet conduit has a first end rigidly attached to the accumulator and a second end configured for attachment to the vacuum-assist waste removal system, the wastewater outlet conduit being configured for directing wastewater from the accumulator to the vacuum-assist waste removal system. An air intake conduit has a first end rigidly attached to the accumulator and a second end spaced from the first end, the air intake conduit being configured for allowing flow of air into the accumulator through the air intake conduit when the vacuum-assist waste removal system is removing wastewater from the accumulator through the wastewater outlet conduit. A sensor conduit has a first end rigidly attached to the accumulator and a second end spaced from the first end, the sensor conduit configured for at least assisting in at least one of generating a signal and relaying a signal when a level of the wastewater in the accumulator reaches a predetermined level, the signal indicating that the vacuum-assist waste removal system should remove the wastewater from the accumulator by applying suction to the second end of the wastewater outlet conduit. The wastewater outlet conduit, the air intake conduit, and the sensor conduit are configured with the accumulator as a unit, the unit being substantially rigid sufficiently self-supporting to be transportable in a peripherally frameless configuration. Various options and modifications are possible.
For example, the accumulator may be a container having a bottom, sides, and a top defining an interior volume for holding the wastewater. Each of the wastewater outlet conduit, the air intake conduit, and the sensor conduit may communicate with the interior of the container through the top of the container.
The sensor conduit may be a tube extending into the interior volume of the container, the first end of the sensor conduit located at a height within the container so that when the wastewater in the container reaches the predetermined level the signal is generated. The signal may be generated by a pressure sensor after a level of the wastewater in the container rises to the height of and closes the first end of the sensor conduit. The pressure sensor may be located proximate the second end of the sensor conduit. The signal may be generated by a float sensor in the container after a level of the wastewater in the container rises to the predetermined level actuates the float sensor, and the float sensor may communicate with the vacuum-assist waste removal system via wiring extending through the sensor conduit.
A wastewater conduit may be communication with the wastewater inlet opening, the wastewater conduit receiving wastewater from at least one fixture. The assembly may include two of the air intake conduits for providing flow of air into the accumulator during the suctioning of wastewater from the accumulator. At least one of the wastewater outlet conduit, the air intake conduit, and the sensor conduit may be attached directly to the accumulator. The at least one of the wastewater outlet conduit, the air intake conduit, and the sensor conduit may be attached to the accumulator by at least one of welding, gluing, threading, and clamping. At least one sleeve may be fixedly attached to the accumulator, and wherein one of the wastewater outlet conduit, the air intake conduit, and the sensor conduit extends at least into the sleeve and is attached thereto. The one of the wastewater outlet conduit, the air intake conduit, and the sensor conduit may extend through the sleeve and is attached to the sleeve by at least one of welding, gluing, threading, and clamping. A plurality of the sleeves may be provided, and wherein each of the wastewater outlet conduit, the air intake conduit, and the sensor conduit is attached to a respective one of the sleeves.
The accumulator may have a width of no more than 2⅞ inches. Also, the accumulator may have a width of about 2¼ inches. At least one of the wastewater outlet conduit, the air intake conduit, and the sensor conduit may include a pipe made of a pipe having a 1½ inch outer diameter. The pipe may be made of one of PVC, stainless steel, lead, or cast iron.
The disclosure is also related to a plumbing fixture installation comprising the self-supporting vacuum plumbing assembly as above and further including the plumbing fixture, the plumbing fixture having an outlet communicatively attached to the wastewater inlet opening of the accumulator so that wastewater from the plumbing fixture is transmitted to the accumulator. If so, a wall may be provided having at least one wall surface, the fixture being mounted on one side of the wall surface and the self-supporting vacuum plumbing assembly being mounted on an opposite side of the wall surface. Also, the wall may have two wall surfaces defining a cavity therebetween, the fixture being mounted on an outer side of one of the wall surfaces and the self-supporting vacuum plumbing assembly being mounted in the cavity between the two wall surfaces. The wall may be a modular wall, the modular wall being a prefabricated structure. The cavity may have a width between the two wall surfaces of no greater than 2⅞ inches. Also, the assembly may have a width of from ¼ to ½ inches less than the width of the cavity so that the assembly fits within the cavity.
The installation may further include a water supply for supplying water to the fixture. The water supply may include a hot water conduit and a cold water conduit. The installation may further include a wiring conduit attached to the wall, the wiring conduit having a first end proximate an attachment location of the plumbing fixture and a second end configured for attachment to wiring of the vacuum-assist waste removal system, and the installation may also include the wiring within the wiring conduit, the wiring within the wiring conduit including wiring for at least one of providing electrical power and providing electrical signaling. The installation may also include at least one of an electrical connector and at least one signaling device connected to the wiring and accessible from the one side of the wall on which the fixture is located. A bottom of the container may be configured for engagement with a lower surface of cavity within the modular wall. At least one brace may be provided for mounting at least one additional item to at least one of the assembly and the wall, the additional item including one of a water supply and a wiring conduit.
In some aspects, the installation may further include the vacuum-assist waste removal system, and may also further including the water supply for supplying water to the fixture.
More details of the present disclosure are set forth in the drawings.
Detailed reference will now be made to the drawings in which examples embodying the present disclosure are shown. The detailed description uses numeral and letter designations to refer to features in the drawings. Like or similar reference numerals in the drawings and description have been used to refer to like or similar parts of the disclosure.
The drawings and detailed description provide a full and enabling description of the disclosure and the manner and process of making and using it. Each embodiment is provided by way of explanation of the subject matter not limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the disclosed subject matter without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment may be used with another embodiment to yield a still further embodiment.
It should be understood that the building in which such structures are located can be any type, including commercial, residential, institutional, medical, single-story, multi-story, new construction, retrofit or remodel, stick built, modular, or prefabricated, enclosed, indoor/outdoor, or outdoor shelter, built on a slab, built on a raised foundation or over a basement or crawlspace, etc. Thus, no limitation should be placed on the types of buildings in which the disclosed plumbing assemblies can be used. Also, the assemblies may be used within interior walls, exterior walls, such as stick-built or pre-fabricated 2×4 or other sizes of lumber walls, within metal-framed walls, uninsulated walls or walls insulated for thermal and/or sound purposes, etc. Conventional 2×4 lumber walls would have a maximum interior width of 3.5 inches, due to sizing of the 2×4 pieces used. The assemblies herein have particular utility within pre-assembled modular walls, but the assemblies can be used within or against any pre-made or on-site assembled wall structures, or even apart from walls, and no limitation as to utility of the disclosed assemblies should be taken from the examples shown herein. Conventional modular walls, such as those available from KI or other companies, are often (by design) thinner than conventional stick-built walls, and may have an external width of 3.5 inches between opposite wall surfaces, depending on application, leaving even less space between walls for plumbing and electrical fixtures.
As shown in the figures, the disclosed example of a fixture is a sink. It should be understood that no limitation on plumbing fixtures is intended by the examples used herein. Plumbing fixtures may be any of those used in settings such as commercial, residential, medical, dental, manufacturing, institutional, stadiums, arenas, theaters, restaurants, bakeries, and other food preparation sites, laundromats, etc. For example, plumbing fixtures could be one or more of sinks, toilets, urinals, bidets, showers, water fountains, bottle fillers, hand and eyewash stations, dental air and water supply, faucets, spickets, home and commercial appliances or equipment, or others. Also, some plumbing fixtures may include more than one of the above, such as sink and toilet units used in institutions. Thus, no limitation should be taken on the type of plumbing fixture(s) that could be used with the assemblies disclosed herein.
Four examples of assemblies will now be discussed in turn, in view of the general system description above using a rigid, self-supporting vacuum plumbing assembly for attaching a plumbing fixture to a vacuum-assist waste removal system.
Accumulator 26 is a vessel for capturing and storing wastewater from a plumbing fixture 22, such as the depicted sink 34. Accumulator 26 may be a metal or plastic box or other shaped vessel having an inlet 36 for receiving water that runs out of the plumbing fixture, such as the through a conventional drain piping 38 (metal or PVC), such as the depicted drain and sink trap. Inlet 36 may attach to drain piping 38 via a short pipe section 40 configured, for example, with threading or other connection structure, to matingly receive and attach to the drain piping, although any waterproof permanent or removable method of attachment is possible. As illustrated, accumulator 26 is a metal box of about 18 gallons, formed of stainless steel plates, with dimensions of 2¼ inches (width W), by about 14 inches (length L) and about 18 inches (height H).
Other sizes, shapes, constructions, etc., could be employed based on the desired location, application, type, or number of fixtures served, etc. For example, the volume could be maintained but the accumulator resized by altering two or more of the three dimensions. Also, the volume could be altered by modifying at least one of the dimensions. The 2¼ width accumulator has particular utility as a “slim-fit” design that is readily able to be fit within conventional walls and may be able to be fit within walls that wider conventional accumulators, connectors, and frames do not.
Wastewater outlet conduit 28 may be for example a ½ inch to 1 inch pipe suitable for suctioning of wastewater from accumulator 26. Air intake conduit 30 and sensor conduit 32 may if desired be larger, such as 1½. To maintain a slimmer profile for the assembly, two of such 1½ inch air intake conduits could be employed, rather than upsizing the one air intake conduit and thereby requiring a wider accumulator or attachment hardware.
As shown in
If accumulator 26 is metallic, conduits 28, 30, and 32 may also be metallic and rigidly attached to the accumulator via welds 28a, 30a, and 32a at openings 28b, 30b, and 32b in top wall 50 of accumulator 26 (see
The first ends 28c, 30c, and 32c may extend different lengths into accumulator 26. For example, wastewater outlet conduit 28 may extend into accumulator so an opening 28e of the conduit is situated near a bottom wall 52 of accumulator 26 to facilitate substantial emptying of the accumulator via suction without clogging opening 28e. If desired bottom wall may be configured to slant toward opening 28e to collect and facilitate suctioning of wastewater through end 28c. Air intake conduit 30 need only extend a small way into accumulator, so its opening 30e may be near top wall 50. Sensor conduit 32 may extend into accumulator 26, preferably with opening 32e at a height below that of inlet 36. Sensor conduit 32 can be connected at its open end to a pressure sensing device PS so that when water level within accumulator 26 reaches and thereby closes opening 32e a signal is generated by the sensor, indicating the vacuum-assist waste removal system section device S should operate to drain accumulator 26.
Accumulator 26 may be attached to a lower surface 54 by hardware, such as flanges 56 and screws 58 (as shown), or glue or adhesive, etc. Lower surface 54 may be a floor or may be a surface within a wall or a modular wall (as shown in
Assembly 20 may be formed of a monolithic (molded plastic such as PVC, if desired, rather than being assembled from parts 26, 28, 30, and 32. Such construction provided even more efficiency in manufacturing while still provided the benefits of a rigid shipping and installation ready structure.
Regardless of the options used, assembly 20 provides a simplified construction useful for installing vacuum-assist plumbing assemblies. The simplified structure is rigid enough to avoid use of a frame for manufacturing, shipping, or installation purposes. Thus, efficiencies are achieved. Also, the simplified structure of sliding conduits 28, 30, and 32 into openings 28b, 30b, and 32b in top wall 50 and sealing there with a weld or the like allows a slim profile that may be desirable in some applications. In particular, the width of the assembly 20 need not be any more than the width W of accumulator 26 (see
As shown in
Use of sleeves provides additional rigidity to assembly 120 while still maintaining a slim assembly and highly simplified assembly, without requiring certain conventional plumbing connectors. The slim-fit sizes of 2¼ and 2¾ inches noted above are still possible with this embodiment, although accumulator 126 could be made ¼ to ½ inch wider to accommodate the sleeves.
The above examples of self-supporting assemblies for attaching plumbing fixtures to a water supply system and to a vacuum-assist waste removal system thus provide various benefits. It should be understood that aspects of the above examples can be combined in different ways to achieve still further examples. All such variations are within the scope of the present disclosure, as defined by the appended claims.
This application is a continuation of copending U.S. application Ser. No. 17/525,033, filed Nov. 12, 2021, and claims benefit to U.S. Provisional Patent Application No. 63/271,409, dated Oct. 25, 2021, both of which are incorporated by reference herein.
Number | Name | Date | Kind |
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3230549 | McMurtrie | Jan 1966 | A |
3694973 | Unger | Oct 1972 | A |
4919164 | Barenburg | Apr 1990 | A |
6305403 | von Palffy | Oct 2001 | B1 |
6837258 | Loreto | Jan 2005 | B1 |
11788270 | Massa | Oct 2023 | B1 |
20220403633 | Zinn | Dec 2022 | A1 |
Number | Date | Country | |
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63271409 | Oct 2021 | US |
Number | Date | Country | |
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Parent | 17525033 | Nov 2021 | US |
Child | 18472396 | US |