Abstract:
A drain assembly is provided that eliminates the need for reconfiguring of existing plumbing during installation of a deep-sink assembly while maintaining a suitable working height. The drain assembly including a hollow body, a valve within the body and a mount to operably connect the valve within the hollow body. The hollow body includes an inlet, an outlet, and an inner wall positioned between the inlet and the outlet. A fluid path enters the inlet of the body in a first direction and is diverted to a second direction substantially perpendicular to the first direction by the inner wall. The diverted fluid path exits the body moving in the second direction. The mount is located at least partially within the outlet.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to an improved drain assembly for a sink and a replacement deep-sink assembly utilizing the improved drain assembly.  
         BACKGROUND OF THE INVENTION  
         [0002]    Commercial establishments, such as restaurants, and institutions typically have sinks of large capacity to be able to wash dishes, pots, pans, and like items or to rinse such items of left-over materials prior to washing these items in automatic dishwashers. Because of the large capacities of these sinks and the chemicals employed in the washing or rinsing operation, the use of a simple stopper or stainer to plug up the drain opening of such sinks to fill the sinks with water are generally not used. Instead, these sinks have had manually operated valves installed in the drain lines from the sinks to open and close the drain lines. Typically, the valves have been provided as part of a drain assembly. For example, these valves have been of a stopper-type which employ a plunger having a head for sealing off a drain opening and a stem which depends through the opening into the drain line. In addition, these types of valves employ a lever system for moving the plunger up and down to open and close the drain assembly. Typically, these lever systems have a handle which can be manually operated by the user. In alternative constructions, the plunger may be actuated by a twisting motion utilizing a cam. Other valves have also been known which employ closure bodies with a through opening of rectangular or cylindrical shape so as to conduct a flow therethrough when in an open position. For example, U.S. Pat. No. 6,058,526, issued to Parisi et al., hereby incorporated by reference, discloses a drain assembly having a closure body with a cylindrical through opening. Various types of manual controls and handles have been provided for rotating the closure member between the open and closed positions when desired.  
           [0003]    The drain assemblies of the prior art that utilize manually operated valves installed within the drain assembly are usually designed to have a single, vertical fluid path through the drain assembly. In other words, the prior art drain assemblies each have an inlet located at a hole in the bottom of the sink basin, and an outlet located several inches directly below the inlet. The valve and a means for operating the valve is located between the inlet and the outlet. If it is desired to alter the fluid path, for example to connect the drain to plumbing located in a wall behind the sink, an appropriately angled pipe fitting must be attached to the outlet of the drain assembly.  
           [0004]    [0004]FIG. 1 shows a prior art drain assembly that has a single, vertical fluid path traveling through the drain assembly. Drain assembly  210  includes inlet  220  located at the top of the drain, and outlet  230  located at the bottom of the drain directly below inlet  220 . The direction of the fluid path traveling through drain  210  is unaltered between inlet  220  and outlet  230 . A valve is located within drain  210  to regulate the flow of fluid along the fluid path. Handle  240  is attached to the valve for easy opening and closing of the valve by an operator. Drain  210  includes an overflow inlet located on the side of the drain. Overflow inlet  225  is positioned to allow fluid traveling from an overflow drain located in the sink to bypass the valve of drain  210  and thus prevent overfilling and overflowing of the sink.  
           [0005]    [0005]FIG. 3 shows inlet  220  of drain  210  attached to sink  250 . The inlet of elbow  235  is attached to outlet  230  of drain  210 . Elbow  235  comprises a pipe having a ninety degree bend to alter the direction of the fluid path exiting drain  210  from a vertical direction to a horizontal direction. The outlet of elbow  235  can be attached to a sewer pipe that connects to a sewer line. The sewer pipe ordinarily runs into the wall directly behind the sink. The height of this pipe is usually determined by the depth of the sink that is to be installed. It is preferable to maintain a sink working height C between thirty and thirty-four inches. Thus, the deeper the sink basin, the lower the sink-base height. Sewer pipe height A will generally be sink-base height B less the height of drain  210  and elbow  235 .  
           [0006]    Many restaurants and commercial kitchens are constructed to include a large capacity rinsing sink having a basin depth D of twelve to fourteen inches. To maintain a working height C of thirty-four inches for a sink having basin depth D of fourteen inches, results in a sink-base height B of twenty inches. Utilizing prior art drain  210  and elbow  235  with this assembly results in a sewer pipe height A of thirteen inches.  
           [0007]    A common problem with the use of the combination of prior art drain  210  and elbow  235  results when a standard large capacity rinsing sink (i.e. basin depth D of fourteen inches) is to be replaced by an extra-large capacity sink for a pot and pan washing machine, such as the machine disclosed in this inventor&#39;s U.S. Pat. No. 4,773,436, which is incorporated by reference herein. An extra-large capacity sink usually has a basin depth D of eighteen to nineteen inches. To maintain a working height C of thirty-four inches for a sink having basin depth D of eighteen inches, requires a sewer pipe height A of nine inches. If the original sink had a sewer pipe height A of thirteen inches, a significant amount of plumbing work is required to reconfigure the sewer line. This plumbing work often includes tearing out a portion of the wall behind the sink, reconfiguring the existing plumbing located behind the wall, and rebuilding the wall. The cost associated with reconfiguring existing plumbing usually ranges between $200 to $300 per installation. Thus, a significant cost savings could be achieved if the need to reconfigure the existing plumbing was eliminated.  
           [0008]    In addition to the costs associated with reconfiguring existing plumbing, the use of the prior art drain and elbow combination with an extra-large capacity sink includes the disadvantage of reducing the amount of usable space located below the sink. Most commercial kitchen sinks require grease traps to catch the grease that is washed off of the pots and pans. Most standard grease traps are ten inches or more in height. As discussed above, to maintain a suitable working height C for sink  250 , sewer pipe height A will be approximately nine inches. A standard grease trap will not be able to fit below such a sink configuration. Thus the grease trap must either be located in another location, wasting usable space, or a special low profile grease trap must be used. Low profile grease traps have a larger footprint than standard grease traps, and therefore have a lower height; however, low profile grease traps cost approximately twenty percent more than standard grease traps.  
           [0009]    It is desirable to design an extra-large capacity sink and drain arrangement that can be used to replace an existing sink and drain configuration without requiring expensive reconfiguration of the existing plumbing. It is also desirable to design a drain that can be used in combination with a sink having a relatively deep basin to provide a maximum amount of usable space below the sink.  
         SUMMARY OF THE INVENTION  
         [0010]    A principal object of the instant invention is to provide a drain-valve assembly for use in combination with a deep sink assembly that can provide a maximum amount of usable space below the sink. It is also an object of the instant invention to provide a drain-valve assembly that will eliminate the need for costly reconfiguring of existing plumbing when an existing sink is replaced with a deeper sink.  
           [0011]    The above described objectives are achieved through the use of a drain assembly including a one piece hollow body, a valve within the body, and a mount to operably connect the valve to the body. The body includes an inlet, an outlet, and an inner wall positioned between the inlet and the outlet. A fluid path enters the inlet of the body in a first direction and is diverted to a second direction substantially perpendicular to the first direction by the inner wall. The fluid path then exits the outlet of the body in the second direction. The mount is located at least partially within the outlet.  
           [0012]    The present invention diverts the fluid path within the drain assembly, thus eliminating the need for the separate elbow attachment located at the outlet of the prior art drains. The elimination of the elbow minimizes the difference between the height of the sewer pipe and the height of the sink-base. The use of the instant invention allows for the easy replacement of an existing sink with a new, deeper basin sink, without requiring reconfiguration of the existing plumbing. This results in a substantial cost and time savings to the installer.  
           [0013]    The instant invention also increases the required sewer pipe height for deep basin sinks while maintaining a suitable working height for the sink. By increasing the sewer pipe height, the amount of usable space directly below the sink is maximized. The space directly below the sink can be used to store a grease trap, which is commonly used on most commercial sink assemblies.  
           [0014]    The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention.  
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0015]    Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.  
         [0016]    [0016]FIG. 1 is a perspective view of a prior art drain assembly.  
         [0017]    [0017]FIG. 2 is a perspective view of the drain assembly of the instant invention.  
         [0018]    [0018]FIG. 3 is a side elevation view of the prior art drain assembly of FIG. 1 incorporated into a sink assembly.  
         [0019]    [0019]FIG. 4 is a side elevation view of the drain assembly of FIG. 2 incorporated into a sink assembly.  
         [0020]    [0020]FIG. 5 is a rear elevation view of the drain assembly of FIG. 2.  
         [0021]    [0021]FIG. 6 is a rear elevation view of a sink assembly of the instant invention.  
         [0022]    [0022]FIG. 7 is a front elevation view of the sink assembly of FIG. 6, showing a drain assembly in partial cut-out.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0023]    Preferred embodiments of the present invention are hereinafter described with reference to the accompanying drawings.  
         [0024]    Referring to FIG. 2, a perspective view of the drain assembly of the instant invention is provided. FIG. 2, shows drain  10  which comprises a hollow body. Hollow body  13  includes inlet  20 , and drain outlet  30 . Inlet  20  is located at the top of body  13 , and outlet  30  is located at the back side of drain body  13 .  
         [0025]    Inlet  20  includes annular flange  21 , and flange nut  22  threaded to threads  24  of body  13 . As is shown in the partial cut-away of FIG. 7, drain  10  is placed through an opening in the bottom of sink  50 . Flange  21  seats about the opening on the inside of the basin of sink  50  and body  13  extends outside of the basin. Flange nut  22  is threaded onto body  13  from the outside of the basin. Flange nut  22  is tightened against the opening in sink  50  to secure drain  10  into position.  
         [0026]    In an alternative embodiment, inlet  21  includes an internal thread and flange  21  seats about an opening outside the basin of sink  50 . A second annular flange seats about an opening inside the basin of sink  50 . The second flange includes an external thread that passes through the sink opening to engage the internal threads of inlet  20  and secure drain  10  to sink  50 .  
         [0027]    [0027]FIG. 5 is a rear view of drain  10  showing outlet  30 . Support member (or mount)  35  is partially located within outlet  30 . Mount  35  is attached to the interior of hollow body  13 . Valve  45  is attached to mount  35  at rotatable connection  37 .  
         [0028]    The rotatable valve of the preferred embodiment is described in detail in U.S. Pat. No. 6,058,526, incorporated herein by reference. Valve  45  is a hollow ball valve including an operating means that is rotated between a closed and an open position using handle  40  to control to flow of fluid through hollow body  13 . Valve  45  has a spherically shaped body with a tubular bore disposed axially of inlet  20  when in an open position, while being disposed transversely of inlet  20  when in a closed position. Valve  45  includes a socket on one side to accept handle  40 , and a pin on the opposite side of the socket to fit into an aperture of mount  35  and form rotatable connection  37 .  
         [0029]    The means for operating valve  45  can include a valve operating handle  40 . The operating handle is located on the front side of drain body  13  directly opposite of outlet  30 . Valve operating handle  40  extends into body  13  through a threaded aperture to connect with hollow ball valve  45 . Handle  40  is rotatably connected to body  13  using handle nut  42  that engages with the threads of the aperture. Handle  40  extends out away from body  13 , and includes grip  44  for easy rotation by an operator. FIG. 7 shows handle  40  extending out towards the front side of sink  50 .  
         [0030]    An alternative embodiment includes a stopper-type valve instead of the ball valve of the instant invention. In such an embodiment, valve  45  comprises a cylindrical head positioned transversely to inlet  20 . Valve  45  includes a stem protruding transversely from the cylindrical head into body  13  of drain  10 . The stem connects to a cam that is rotated by handle  40 . As the cam is rotated, the cylindrical head of valve  45  travels up and down in a direction axial to inlet  20 . When the cylindrical head is in a down position it seals inlet  20  to prevent the flow of fluid through the drain. When the head is up fluid is permitted to flow through the drain. The side of the cam opposite the handle, includes a pin that is rotatably connected to mount  35  to form a rotatable connection. The stem can be positioned to slide within axial channels located on the interior of body  13  to provide smooth linear movement of the head.  
         [0031]    [0031]FIG. 5 shows inner wall  15  of hollow body  13 . In the preferred embodiment, inner wall  15  is gradually curved between inlet and outlet to prevent accumulation of fluid or debris, while diverting the path of fluid traveling through drain  10 . In operation, valve  45  is rotated into an open position, fluid enters hollow body  13  at inlet  20  in a first direction that is substantially vertical. The fluid then contacts inner wall  15  and the fluid path is diverted to a second direction that is substantially perpendicular to the first direction. The fluid then exits body  13  traveling in the second direction through outlet  30 .  
         [0032]    [0032]FIG. 6 shows a rear view of a deep basin sink assembly of the instant invention that can be used as a replacement for an existing sink assembly. Drain  10  is connected to the bottom side of deep-sink  50 . Outlet  30  of drain  10  is connected to sewer pipe  65  of the existing plumbing. The existing plumbing can include a grease trap. Because of the space savings obtained through the use of the instant invention, grease trap  60  can be positioned below sink  50 , as is shown in FIG. 7.  
         [0033]    The principal benefit of the instant invention is easily identified by a comparison of the deep-sink assembly of FIG. 4 with the prior art sink assembly of FIG. 3. An example will now be discussed wherein sewer pipe height A of the prior art sink assembly is thirteen inches, and sewer pipe height A′ of the instant invention deep-sink assembly is also thirteen inches. Additionally, basin depth D of the prior art assembly is eighteen inches, and basin depth D′ of the inventive deep-sink assembly is also eighteen inches. In this example, prior art drain assembly will result in a working height C of thirty-eight inches, and a sink-base height B of twenty inches. The prior art requires the use of leg extensions  255  to raise the sink to the proper height. Alternatively, the inventive deep-sink assembly will result in a working height C′ of thirty-four inches, a sink-base height B′ of sixteen inches, and does not require the use of any leg extensions. As discussed above in the Background of the Invention section, an ideal working height ranges between thirty and thirty-four inches. Anything greater than thirty-four inches will often require the operator of the sink to use a step stool, or some other booster, to properly operate the sink. Such is inconvenient for the sink operator, and now unnecessary due to the instant invention.  
         [0034]    In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described. Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense.  
         [0035]    Having now described the features, discoveries and principles of the invention, the manner in which the inventive drain assembly is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.  
         [0036]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.