BACKGROUND OF THE INVENTION
1. Field of the Invention
This present invention pertains to a drain pipe or drain body that attaches to a sink at a drain opening for draining water from the sink and more particularly to a drain pipe that can be used with a sink that has or that does not have an overflow port.
2. Description of the Related Art
One type of sink that is used in a bathroom or restroom has an overflow port for diverting water into a drain pipe below a drain opening in the sink in the event the drain opening is closed while water continues to run into the sink. The drain pipe has a port, and an overflow conduit, which is typically built into the sink, allows water to flow from the sink's overflow port to the drain pipe's overflow port and into the drain pipe. Another type of sink, which is known as a vessel sink, does not have an overflow port. A drain pipe that does not have an overflow port is used for the vessel sink. Retail stores and plumbing supply businesses typically keep an inventory of each type of drain pipe. Sometimes a mistake is made, and a drain pipe with an overflow port is installed on a vessel sink that does not have and overflow port. The overflow port on the drain pipe may not be sealed due a difference in the thickness of the two types of sinks, which allows water to leak from the drain pipe's overflow port. Another mistake that can be made is to install a drain pipe that does not have an overflow port in a sink that has an overflow port, which causes the sink's overflow port to be nonfunctional.
SUMMARY OF THE INVENTION
A drain body is provided for connection to a sink having a drain opening, where the drain body includes a pipe having a sidewall, a length and opposing upper and lower ends, where the sidewall defines an interior fluid flow passageway in the pipe; a flange on the upper end that extends radially, where the flange and pipe are sized so that the pipe will pass through the drain opening, and where the flange will not pass through the drain opening; a port in the sidewall for receiving water from the sink through an overflow channel if the sink has an overflow port; and means for sealing the port in the sidewall if the sink does not have an overflow port.
Means for sealing the port in the sidewall of the pipe include a cover and a sleeve. Types of covers include a resilient grommet, a hole plug pressed into the port after the pipe is made, a hole plug that has external threads that match external threads on the sidewall of the pipe, a knock-out hole plug formed integral with pipe that can be broken out and removed to provide the port in the sidewall and a sheet with adhesive that is glued or bonded to the sidewall to cover and seal the port. The sleeve can be an inside sleeve or an outside sleeve, either of which is proximate to the sidewall for covering the sealing the port. The inside sleeve may be a standalone tube or a tube that is attached to the underside flange. The outside sleeve may be in threaded engagement with external male threads on the sidewall of the pipe.
A kit can be made and sold that includes a drain pipe having a sidewall with a port in its sidewall, a drain flange formed integral with or attachable to an upper end of the drain pipe and at least one means for covering and sealing the port in the sidewall of the drain pipe. The kit can be used with a sink that does not have an overflow port by using the means for covering and sealing the port in the sidewall of the drain pipe. The kit can be used with a sink that has an overflow port by not using the means for covering and sealing the port in the sidewall of the drain pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention can be obtained when the detailed description of exemplary embodiments set forth below is considered in conjunction with the attached drawings in which:
FIG. 1 is a cross-section of a side elevation of a sink with an overflow port and a drain pipe with an overflow port in fluid communication with the overflow port of the sink, according to the prior art.
FIG. 2 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 3 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 4 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 5 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 6 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 7 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 8 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 9 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 10 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
FIG. 11 is a cross-section of a side elevation of a drain pipe for a sink, according to the present invention.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
A discussion of the prior art will be helpful in understanding the present invention. FIG. 1 is a side elevation in cross-section of a prior art pop-up drain assembly 10 in a sink or basin 12. The pop-up drain assembly 10 is received in the sink or basin 12, which is typical for a bathroom, restroom or lavatory. Sink 12 has a lower surface 12a that drains into a drain opening 12b. Sink 12 has an overflow port 12c in a side wall 12d. An outer wall 12e and side wall 12d define an overflow conduit or channel 12f, and side wall 12d has an overflow drain port 12g for draining overflow fluid into a port in drain assembly 10. A faucet 14 is mounted on a top deck 12h of sink 12 for supplying water or other fluid to sink 12. Pop-up drain assembly 10 comprises a drain flange 16 that fits down through drain opening 12b in sink 12. Drain flange 16 has a threaded tubular portion extending essentially throughout its full length, and a flange 16b extends radially outwardly on a top end. Flange 16b is shown in FIG. 1 as formed integral with the tubular body of drain flange 16, but FIG. 2 in the present inventors' U.S. application Ser. No. 15/584,030 (Pub. No. 2017/0314244 A1) shows a more typical arrangement in which the flange portion is in threaded engagement with the tubular portion. FIG. 2 in the present inventors' U.S. application Ser. No. 15/584,030 shows a drain pipe that comprises a drain flange and a separate drain tube, which is in a threaded engagement with the drain flange. A gasket or plumber's putty 18 provides a seal between the lower surface 12a of the sink 12 and the flange 16b of drain flange 16. A flexible gasket 20 and a washer 20a are placed around a bottom portion of drain flange 16 and then pressed tightly against a bottom surface of sink 12 with a threaded nut 20b. A drain body 22 is threaded onto a lower end of drain flange 16. Drain body 22 has a wrench flange 22a for receiving a wrench for tightening and loosening drain body 22 with respect to drain flange 16. Drain body 22 has a pivot rod port 22b, and a threaded tubular stub 22c projects radially outwardly from drain body 22. A pivot rod seal 24 is received in stub 22c.
A pivot rod 26 has a stopper end 26a and an outer end 26b. A pivot ball 28 is sealingly received on pivot rod 26 closer to stopper end 26a than outer end 26b. Pivot rod 26 is received in stub 22c such that stopper end 26a is inside the drain body 22, and the stopper ball 28 rests against pivot rod seal 24. A pivot rod cap 30 is threaded onto stub 22c sufficiently tightly to seal pivot ball 28 against pivot rod seal 24, but loose enough to allow pivot ball 28 and pivot rod 26 to pivot. An extension rod 32 having a plurality of holes, which are not shown, is received on outer end 26b of pivot rod 26 and held in place by a clip 32a. Extension rod 32 is bent so as to have two parallel portions 32b and 32c that are perpendicular to the longitudinal axis of the extension rod 32, and each of the two parallel portions has a hole through which a control rod 34 is received. Control rod 34 passes through a faucet port 14a and a sink control rod port 12h. Control rod 34 has a knob 34a at an upper end, and control rod 34 is fastened to extension rod 32 by a set screw 32d.
A stopper 40 is received in drain flange 16 and drain body 22. Stopper 40 has an elongate shaft 40a running its length, which has a longitudinal axis through the center of stopper 40. A cap 40b is located on an upper end while the drain assembly 10 is installed and operational, and a pivot rod receiving member 40c is located on an opposing lower end. The pivot rod receiving member 40c defines an opening through which stopper end 26a of pivot rod 26 protrudes for engaging and moving stopper 40, and pivot rod receiving member 40c may be referred to as open member 40c. Four flanges or fins, referred to collectively as fins 40d, extend longitudinally along shaft 40a and project radially, and fins 40d lie in two perpendicular and intersecting planes. The fins provide structural support for the shaft and center the stopper in the drain pipe.
A vessel sink (not shown) does not have an overflow port or overflow conduit such as overflow port 12c and overflow conduit 12f shown in FIG. 1. The thickness of a vessel sink may be similar to the thickness of side wall 12d in FIG. 1. There have been many instances in which a drain pipe with an overflow port has been installed on a vessel sink, where the overflow port in the drain pipe was not sealed and leaked.
The present invention provides in one embodiment a drain pipe that has an overflow port and a device or a means for covering and sealing the overflow port in the drain pipe when the overflow port is not needed. Consequently, a retail store or a plumbing supply store does not need to have an inventory of both types of drain pipes, as one drain pipe with an overflow port and a means for covering and sealing the overflow port can be used in either application.
With respect to the present invention, FIG. 2 is a side elevation in cross-section of a drain pipe 50 similar to the tubular portion of the drain flange 16 in FIG. 1. Drain pipe 50 is very similar to the drain tube 54b in FIG. 2 of the present inventors' U.S. application Ser. No. 15/584,030 (Pub. No. 2017/0314244 A1). Drain pipe 50 has a sidewall 50a, an upper end 50b, a lower end 50c and a plurality of overflow ports 50d, which are openings through the sidewall 50a. The sidewall 50a defines an interior fluid flow passageway 50e in the drain pipe 50. Overflow ports 50d are shown as having a rectangular shape, but may have any other shape such as circular and square. A grommet 52 has a shape and size suitable for covering and sealing one of the overflow ports 50d. Grommet 52 has a perimeter 52a that is slightly larger than one of the overflow ports 50d defined by the sidewall 50a. Grommet 52 has a groove 52b along the perimeter 52a. The groove 52b is about the same size as, but slightly smaller than, the one of the overflow ports 50d. Grommet 52 is preferably resilient so that it can bend and compress and is preferably made of a rubber or elastomeric material. One grommet 52 is inserted in each overflow port 50d for covering and sealing the overflow ports 50d. The portion of the sidewall 50a that defines one of the ports 50d is received in the groove 52b. The grommet 52 presses against or is close to the sidewall 50a so as to cover and seal one of the overflow ports 50d, thereby preventing water in the interior fluid flow passageway 50e from leaking out through the port 50d. One grommet 52 would be pressed into each overflow port 50d. A kit that includes the drain pipe 50 and a grommet 52 for each overflow port 50d can be sold. The kit can further include a pop-up drain assembly such as described in the present inventors' related applications.
FIG. 3 is a side elevation in cross-section of a drain pipe 60 similar to the drain pipe 50 in FIG. 2. Drain pipe 56 has a sidewall 56a, an upper end 56b, a lower end 56c and a plurality of overflow ports 56d, which are openings through the sidewall 56a. The sidewall 56a defines an interior fluid flow passageway 56e in the drain pipe 56. The sidewall 56a has external male threads 56f. A hole plug 58 is pressed into an overflow port 56d in a tight, sealing fit with the portion of the sidewall 56a that defines the port 56d. The hole plug 58 may protrude outwardly somewhat after installation and may have a smooth outer surface. However, in one embodiment, the hole plug 58 has male threads on an external surface that match with the male threads 56f on the sidewall 56a, and in this embodiment a nut (not shown) having internal female threads can be screwed over the hole plugs 58 to hold them securely engaged with the sidewall 56a to seal the overflow ports 56d.
FIG. 4 is a side elevation in cross-section of a drain pipe 60 similar to the drain pipe 50 in FIG. 2. Drain pipe 60 has a sidewall 60a, an upper end 60b, a lower end 60c, a plurality of overflow ports 60d and an interior fluid flow passageway 60e. A knock-out hole plug 62 covers and seals each of the overflow ports 60d. The knock-out hole plugs 62 are formed integral with the sidewall 60a of the drain pipe 60 or are inserted into overflow ports 60d and fastened to the sidewall 60a to cover and seal the overflow ports 60d. If the drain pipe 60 is to be used with a sink that has an overflow port and an overflow conduit, then the knock-out hole plugs are knocked out, punched out or broken out so that water can flow from the sink's overflow port through the overflow conduit and into the interior fluid flow passageway 60e through the overflow ports 60d. If the drain pipe 60 is to be used with a sink that does not have an overflow port, presumably a vessel sink, then the knock-out hole plugs 62 are left in place so that water does not leak out through the overflow ports 60d. A V-shaped notch 60f can be formed in the sidewall 60a to provide a line of weakness around the perimeter of what will become an overflow port 60d if the knock-out plug 62 is removed from the sidewall 60a.
FIG. 5 is a side elevation in cross-section of a drain pipe 66 similar to the drain pipe 50 in FIG. 2. Drain pipe 66 has a sidewall 66a, an upper end 66b, a lower end 66c, a plurality of overflow ports 66d and an inside surface 66e. A flange 68 has female threads 68a in threaded engagement with the upper end 66b of drain pipe 66. The male and female threads can be reversed, and the flange 68 can be made integral with the drain pipe 66, or a press fit can be used. Flange 68 has an upper, outer surface 68b and an inner, lower surface 68c. A cylindrical, tubular sleeve 68d depends downwardly from the inner, lower surface 68c. A gap is defined between an outer surface 68e and the female threads 68a in the flange 68. The upper end 66b of the drain pipe 66 fits with little clearance (somewhat snugly) in the gap. The tubular sleeve 68d has an upper end 68f attached to or formed integral with the flange 68 and an opposing lower end 68g. The lower end 68g of the sleeve 68d extends below the overflow ports 66d. The outer surface 68e of the sleeve 68d is very close to or proximate to or adjacent to the inside surface 66e of the drain pipe 66 and below the overflow ports 66d, thereby covering and sealing the overflow ports 66d.
FIG. 6 is a side elevation in cross-section of a drain pipe 70 similar to the drain pipe 50 in FIG. 2. Drain pipe 70 has a sidewall 70a, an upper end 70b, a lower end 70c, a plurality of overflow ports 70d and an inside surface 70e. A cylindrical, tubular sleeve 72 has a sidewall 72a, an upper end 72b, a lower end 72c and an outside surface 72d. Sleeve 72 fits inside drain pipe 70 such that the outside surface 72d of sleeve 72 is very close to or proximate to or adjacent to the inside surface 70e of the drain pipe 70. Sleeve 72 has a length long enough to cover the overflow ports 70d in the drain pipe 70. Sleeve 72 can be held in place by a pressure fit, a compression fit, a friction fit or by an adhesive. Sleeve 72 covers and seals the overflow ports 70d.
FIG. 7 is a side elevation in cross-section of a drain pipe 76 similar to the drain pipe 50 in FIG. 2. Drain pipe 76 has a sidewall 76a, an upper end 76b, a lower end 76c, a plurality of overflow ports 76d and an interior fluid flow passageway 76e. A continuous strip or patches 78 of an adhesive-backed or coated material is secured or pressed into engagement with the sidewall 76a for covering and sealing the overflow ports 76d. In its simplest form, a piece of duct tape can be wrapped around sidewall 76a to cover and seal the overflow ports 76d. However, a more elegant solution is envisioned in which the material may be decorative, such as matching or accenting the color of the drain pipe 76, and the material may be a metallic foil or a resilient polymeric material. It may be preferable to thread a nut over the material or to clamp the material to the sidewall 76a in addition to or instead of the adhesive.
FIG. 8 is a side elevation in cross-section of a drain pipe 80 similar to the drain pipe 50 in FIG. 2. Drain pipe 80 has a sidewall 80a, an upper end 80b, a lower end 80c, a plurality of overflow ports 80d and an inside surface 80e. A cylindrical, tubular sleeve 82 has a sidewall 82a, an upper end 82b, a lower end 82c and an outside surface 82d. Sleeve 82 fits inside drain pipe 80 such that the outside surface 82d of sleeve 82 is close to or near the inside surface 80e of the drain pipe 80. Sleeve 82 has a length long enough to cover the overflow ports 80d in the drain pipe 80. Sleeve 82 has an upper circumferential groove 82e near its upper end 82b and a lower circumferential groove 82f near its lower end 82c. An upper O-ring, seal or gasket 82g is received in the upper groove 82e, and a lower O-ring, seal or gasket 82h is received in the lower groove 82f. Sleeve 82 covers and seals the overflow ports 80d. A kit that includes the items described with reference to FIG. 8 and a drain flange can be sold, preferably with the sleeve 82 uninstalled. If the application is for a vessel sink without an overflow port, the seals 82g and 82h can be placed on the sleeve 82, and the sleeve 82 can be inserted into the drain pipe 80 to cover and seal the overflow ports 80d.
FIG. 9 is a side elevation in cross-section of a drain pipe 86 similar to the drain pipe 50 in FIG. 2. Drain pipe 86 has a sidewall 86a, an upper end 86b, a lower end 86c, a plurality of overflow ports 86d and an inside surface 86e. A cylindrical, tubular sleeve 88 has a sidewall 88a, an upper end 88b, a lower end 88c and an outside surface 88d. Sleeve 88 also has a outwardly extending radial flange 88e at its upper end 88b that projects radially with respect to the longitudinal axis of sleeve 88. Sleeve 88 fits inside drain pipe 86 such that the outside surface 88d of sleeve 88 is close to or near the inside surface 86e of the drain pipe 86. Sleeve 88 has a length long enough to cover the overflow ports 86d in the drain pipe 86. A drain flange 90 has a sidewall 90a, an upper end 90b, a lower end 90c, an inside surface 90d of the sidewall 90a, an outside surface 90e of the sidewall 90a, an outwardly extending radial flange 90f that would rest on a bottom surface of a sink and surround a drain opening and an inwardly extending radial flange 90g that provides a shoulder that the upper end 86b of the drain pipe 86 abuts. The upper end 86b of the drain pipe 86 also abuts the radial flange 88e of the sleeve 88. Upper surfaces of the upper ends 88b and 90b of the sleeve 88 and the drain flange 90, respectively, are aligned and would be visible in a sink and would preferably have the appearance of being smooth and continuous. Sleeve 88 may or may not be fastened to the drain flange 90. Sleeve 88 can be held in place by a pressure fit, a compression fit, a friction fit or by an adhesive. Sleeve 88 covers and seals the overflow ports 86d.
FIG. 10 is a side elevation in cross-section of a drain pipe 94 similar to the drain pipe 50 in FIG. 2. Drain pipe 94 has a sidewall 94a, an upper end 94b, a lower end 94c, a plurality of overflow ports 94d and an outside surface 94e of the sidewall 94a. A drain flange 96 has a sidewall 96a, an upper end 96b, a lower end 96c, an inside surface 96d of the sidewall 96a, an outside surface 96e of the sidewall 96a and an outwardly extending radial flange 96f that would rest on a bottom surface of a sink and surround a drain opening. Drain flange 96 is in threaded engagement with drain pipe 94 and together would fit in a drain opening of a sink and would be sealed with the sink. If the sink has an overflow port and an overflow conduit, then overflow water will drain into the overflow ports 94d. However, if the sink is a vessel sink without an overflow port, then water would likely leak out through the ports 94d in the drain pipe 94. To seal the ports 94d in the drain pipe 94 when the drain pipe 94 and the drain flange 96 are used with a vessel sink that does not have an overflow port, an outer sleeve 98 is used to cover and seal the ports 94d. Outer sleeve 98 has an upper portion 98a that has an inside diameter and inside female threads 98b sized and designed to matingly and threadedly engage the outside surface 94e, which has male threads, of the drain pipe 94. The outer sleeve 98 has an upper end 98c and a radial flange 98d that extends radially outwardly with respect to the longitudinal axis of the outer sleeve 98. The outer sleeve 98 and its radial flange 98d can be used together with a gasket or a washer and gasket and/or plumber's putty between the flange 96f and an upper, inner surface of the sink around the drain opening to seal the drain pipe 94 and the drain flange 96 in the drain opening of a vessel sink. The outer sleeve 98 has a lower portion 98e that has an inside surface/diameter 98f that is about the same as the inside diameter of the drain pipe 94. An inwardly tapered transition portion 98g provides a transition between the inside diameter/surface 98b and the inside diameter/surface 98f. Outer sleeve 98 covers and seals the overflow ports 94d in the drain pipe 94 when the sink is a vessel sink. A kit can be sold that includes the drain pipe 94, the drain flange 96 and the outer sleeve 98 along with any washers, gaskets and nuts that may be useful.
FIG. 11 is a side elevation in cross-section of a drain pipe 100 similar to the drain pipe 50 in FIG. 2. Drain pipe 100 has a sidewall 100a, an upper end 100b, a lower end 100c, a plurality of overflow ports 100d and an outside surface 100e of the sidewall 100a, which has male threads 100f. A gasket or seal or resilient ring 102 surrounds and is in close proximity to the sidewall 100a of the drain pipe 100 and is located so as to cover the overflow ports 100d. Resilient ring 104 has an annular shape with an inner surface 102a, an outer surface 102b, an upper surface 102c and a lower surface 102d. A washer 104 is located below the resilient ring 102 and has an upper surface 104a located adjacent to and in contact with the lower surface 102d of the resilient ring 102. Washer 104 has a lower surface 104b. A nut 106 having female threads 106a is in threaded engagement with the male threads 100f on the outer surface 100e of the drain pipe 100. Nut 106 is located below washer 104, and washer 104 is between resilient ring 102 and nut 106. Nut 106 has an upper surface 106b that is that is adjacent to and in contact with the lower surface 104b of the washer 104.
A kit including a drain flange such as drain flange 96 in FIG. 10, the drain pipe 100, the resilient ring 102, the washer 104 and the nut 106 can be made and sold. The kit may also include the flexible gasket 20 shown in FIG. 1. The washer 104 and the nut 106 are likely interchangeable with the washer 20a and the threaded nut 20b in FIG. 1. The resilient ring 102 is more elongated than the gasket 20 in FIG. 1 so that the resilient ring 102 can cover and seal the overflow ports 100d in the drain pipe 100. If the drain pipe 100 is to be used in a conventional sink with an overflow port such as sink 12 in FIG. 1, then the elongated resilient ring 102 is not really needed and a gasket like gasket 20 can be used when fastening the drain pipe 100 in the sink. However, if the drain pipe 100 is to be used in a vessel sink that does not have an overflow port, then the drain flange can be threaded onto the upper end 100b of the drain pipe 100; the lower end 100c of the drain pipe 100 can be dropped through the drain opening in the sink; optionally, a second washer (not shown) can be placed around the drain pipe just below the bottom of the vessel sink; the resilient ring 102 is then placed on the drain pipe below the second washer if one is used or just below and in contact with the bottom of the vessel sink; the washer 104 is placed below and in contact with the lower surface 102d of the resilient ring 102; and the nut 106 is placed below the washer 104 so that the upper surface 106b of the nut 106 is in contact with the lower surface 104b of the washer 104. The nut 106 is tightened, which presses the resilient ring 102 against the bottom of the vessel sink. The gasket, seal or ring 102 is made of a material that is firm, but compressible, which is preferably resilient and waterproof or impervious to water. Suitable materials may include an elastomeric polymeric material, synthetic or natural rubber or a closed-cell foam. Tightening of the nut 106 compresses the ring 102, which presses the inner surface 102a of the ring 102 against the outside surface 100e of the drain pipe 100, thereby covering and sealing the overflow ports 100d of the drain pipe 100.
Having described the invention above, various modifications of the techniques, procedures, materials, and equipment will be apparent to those skilled in the art. It is intended that all such variations within the scope and spirit of the invention be included within the scope of the appended claims.
Patent Grant
10808386
