Drain systems and related methods

A drain system includes a basin and a drain, where a first one of the basin and the drain comprises at least two substantially inflexible protrusions and a second one of the basin and the drain forms at least two apertures. The protrusions and apertures form male-female connections that facilitate positioning and anchoring of the drain in the basin. Further, stoppers/strainer and ball valves for limiting or ceasing water flow through a drain are disclosed. The stoppers/strainers and quarter turn valves may be switch-activated and moved into position by electricity, water pressure, air pressure and the like.

BACKGROUND

Modern wash basins usually contain a drain that provides an escape for waste water. The drain is inserted into a hole in the basin, and a gasket seals around a perimeter of the drain on an underside of the basin. A washer and a basket lock nut secure the gasket to the drain.

Though the parts of the drain are simple, installation of these parts into the wash basin can be a daunting task for an individual. Therefore, installation of a drain is most often a two-person job. One person stands over the basin keeping the drain steady, while the other person lies under the basin using a wrench to tighten or loosen the basket lock nut.

FIG. 1shows a drain system100including a drain101and a basin105. Drain101has a rim102, a basket103, and a stem104. Basin105has an edge113supporting a pair of hot/cold water handles106and a faucet107. A hole108is formed within basin105. Installation of drain101into basin105is accomplished by inserting drain101into hole108from a top side of the basin, then placing a gasket110, a washer111, and a basket lock nut112onto basket103from an underside of basin105. A wrench may be used to tighten basket lock nut112onto threads114of basket103. However, application of force to basket lock nut112frequently results in rotation of drain101rather than independent movement of the basket lock nut.

SUMMARY

In an embodiment, a drain system includes a basin and a drain, where at least one of the basin and the drain forms at least two apertures, and at least one of the basin and the drain comprises at least two substantially inflexible protrusions configured for insertion into the apertures.

In an embodiment, a method for installing a drain system includes: providing a basin and a drain, where at least one of the basin and the drain comprises at least two substantially inflexible protrusions and at least one of the basin and the drain forms at least two apertures; inserting the protrusions into the apertures; and securing the drain to the basin.

In an embodiment, a strainer for preventing solids from entering plumbing includes a circular part having a diameter approximately equal to the internal diameter of a drain and means for maintaining the circular part within the drain. The circular part contains a plurality of orifices.

In an embodiment, a drain includes at least one stopper/strainer disposed within an arm proximal to a drain stem and means for moving the stopper/strainer into and out of the drain stem.

In an embodiment, a drain system includes a quarter turn valve disposed within a drain and an actuator for controlling rotation of the quarter turn valve.

In an embodiment, a drain system includes a quarter turn valve disposed within a drain and a directional vane enclosed within a housing. The directional vane is attached to the quarter turn valve to cause rotation of the quarter turn valve when water flows through the housing.

DETAILED DESCRIPTION

FIG. 2shows one configuration of a basin201forming part of a drain system (400,FIG. 4). Basin201may be similar to basin105ofFIG. 1. Basin201is illustrated with an edge207supporting a pair of hot/cold water handles202, such as handles106ofFIG. 1, and a faucet203, such as faucet107ofFIG. 1. Basin201also forms a hole204, such as hole108ofFIG. 1. Although shown as a sink, basin201may equivalently be a shower, tub or other variation without departing from the scope hereof. In addition, basin201forms at least one aperture205proximal to hole204, where the aperture(s) may be provided by a manufacturer or drilled into an existing basin201by an end user. It will be appreciated that basin201may contain one, two, three, four, five, six or more apertures205, and that aperture(s)205may be formed in one or more shapes, such as oval, circular, square, hexagonal, triangular or irregular.

FIG. 3shows an exemplary drain301of a drain system (400,FIG. 4). Drain301has a rim302and a body312. Body312includes a basket303and a stem304. A gasket305, a washer306, and a basket lock nut307secure drain301to basin201ofFIG. 2. A portion of basket303contains threads311for mating with basket lock nut307. Rim302has at least one protrusion308disposed on an underside310of rim302. Protrusion308is substantially inflexible and has a maximum length L, for example, of approximately 5 mm to 3 cm, and a width of about 5 mm to 3 cm. Protrusion308is typically disposed a distance D of, for example, about 0 mm to 1.5 cm from body312of drain301. When protrusion308is disposed a distance of 0 mm from body312, e.g., when protrusion308forms a part of body312, it will essentially form an extension of basket303that serves to break the rotational symmetry of the circular basket. Protrusion(s)308may be used to align drain301to basin201. Although two protrusions308are shown inFIG. 3, it will be appreciated that more or fewer protrusions, of various styles, may be utilized. In some embodiments, protrusion(s)308may be threaded for receiving a locking nut.

As used herein, the term “substantially inflexible protrusion” refers to a protrusion that is not readily bent and which is generally incapable of changing shape or position.

FIG. 4shows an assembly schematic of drain system400. System400includes drain301and basin201. As shown, body312of drain301is aligned with hole204, and protrusions308are aligned with apertures205. Protrusions308may be used as male connectors to mate with apertures205, which form female receptacles. It will be appreciated that apertures205may be formed as recesses configured as cup-like receptacles or as open-ended conduits. If aperture205is an open-ended conduit, a gasket may be used at the aperture to prevent leakage. Once protrusions308enter apertures205, the position of drain301becomes fixed relative to basin201. Rotational force may then be applied to tighten or loosen basket lock nut307,FIG. 3, without inducing spinning of drain301. Thus, drain systems, as disclosed herein, may be assembled by a single person.

FIG. 5shows an assembly schematic of a drain system500. A drain501has a rim504and a body503. A basin506may include at least one protrusion505disposed proximal a hole507. Drain501may form at least one aperture508within rim504. It will be appreciated that aperture508may be formed as a recess configured as a cup-like receptacle or as an open-ended conduit. If aperture508is an open-ended conduit, a gasket may be used at the aperture to prevent leakage. Assembly of drain system500may be accomplished by aligning body503with hole507, and aperture(s)508with protrusion(s)505. Mating of drain501with basin506in this orientation prevents drain501from rotating when an external rotational force is applied to a basket lock nut (e.g., basket lock nut307,FIG. 3).

Components of drain systems400and500may be fabricated, for example, from one or more materials selected from stainless steel, metals, metal alloys, plastics, enamels, porcelain, ceramics, glass, soapstone, concrete, terrazzo, and combinations thereof.

Following installation of drain301,501, plumbing (601,FIG. 6) may be connected to stem304,504using a stem lock nut602. In one example, drain301,501joins directly with a garbage disposal, which then connects to plumbing601.

FIG. 7shows an exemplary method700for installing drain system400,500. Method700starts with step702. In step702, a basin201,506and a drain301,501are provided, where a first one of the basin and the drain comprises at least two substantially inflexible protrusions308,505and a second one of the basin and the drain forms at least two apertures205,508. Method700continues with step704. In step704, protrusion(s)308,505are inserted into apertures205,508, which prevent drain301,501from rotating when force is applied to basket lock nut307. Tightening of basket lock nut307secures drain301,501to basin201,506in step706. The combination of steps702-706results in an assembled drain system400,500. When steps702-706are performed in reverse order, drain301,501may be removed from basin201,506.

FIG. 8shows an exemplary cross-sectional side view of a stopper800and a strainer804disposed within a drain810. Stopper800is configured to seal drain810in a water-tight manner when stopper800is closed, e.g., using a handle802. Strainer804includes a circular part812forming a base of a cylinder having a wall820. A threaded portion at the distal end of strainer804is configured for mating with a threaded portion of drain810. Strainer804includes orifices806that provide passage for water through strainer804into drain810when stopper800is open. Orifices806, which may be disposed within circular part812and/or wall820, trap solid particles such as hair, food, etc. within strainer804.

In one embodiment, strainer804may contain a central post808disposed at a center point of circular part812and perpendicular thereto. Post808may contain a threaded top portion814for mating with a complementary threaded portion816of stopper800. In one example of operation, a user may rotate handle802counterclockwise to open stopper800, thus allowing water to flow from a basin through orifices806into drain810. On the other hand, stopper800may be rotated clockwise to a closed position, thereby sealing stopper800and stopping the flow of water through drain810. Those skilled in the art will further appreciate that strainer804may be used to collect solid particles without the use of stopper800.

FIG. 9shows an exemplary top plan view of a switch-activated stopper/strainer900disposed inside a drain902. Stopper/strainer900is generally a circular part that optionally contains orifices904, e.g., when a strainer configuration is desired. Orifices904may, in one example, be formed by a wire mesh. A drain system may be configured with a switch (1018,FIG. 10) or valve (1108,FIG. 11) that allows water pressure, air pressure, a solenoid, a motor or the like to move stopper/strainer900into and out of drain902, thereby controlling the flow of water from a basin to plumbing.

FIG. 10shows an exemplary cross-sectional side view of a drain system including an electrically-activated stopper/strainer1010.FIG. 10shows drain1000having a stem1002, which is configured to receive an arm1004. Stopper/strainer1010may be disposed, at least partially, inside arm1004from which stopper/strainer1010extends and retracts. In the embodiment shown, stopper/strainer1010is connected to a piston1012. Movement of piston1012is controlled by a controller1014, such as a motor or solenoid valve. Controller1014connects to a switch1018and a power source1016. Switch1018activates controller1014to extend or retract piston1012and stopper/strainer1010into and out of stem1002.

In an example of operation, stopper/strainer1010may be disposed within arm1004until a user closes switch1018. With switch1018closed, power is supplied to controller1014, which moves piston1012and stopper/strainer1010into stem1002. When switch1018is opened, supply of power to controller1014may cease and piston1012and stopper/strainer1010may retract out of stem1002.

In another example, stopper/strainer1010may be disposed within stem1002until a user closes switch1018. When switch1018is closed, power is supplied to controller1014, which moves piston1012and stopper/strainer1010into arm1004. When switch1018is opened, supply of power to controller1014may cease and piston1012and stopper/strainer101may extend into stem1002.

FIG. 11shows an exemplary cross-sectional side view of a drain system1100. System1100includes a stopper/strainer1102operated by air or water pressure1112. A drain1110has a stem1114, which is configured to receive an arm1104. In the embodiment shown, arm1104forms part of a water line1106that connects to a pipe1122that provides water (e.g., to a faucet102,203). A valve1108, which may be a T-valve, controls the flow of water through water line1106. Water line1106preferably has a relatively small diameter (e.g., between about one inch and one-quarter inch) in order to provide high water pressure1112. A spring1116is disposed within arm1104and is fixedly connected to stopper/strainer1102. Spring1116biases stopper/strainer1102in an open (retracted) position. A user may engage or disengage stopper/strainer1102by turning valve1108to control the flow of water from pipe1122to water line1106. When valve1108is open, water pressure1112builds within water line1106and eventually overcomes the biasing pressure of spring1116, thus urging stopper/strainer1102into a closed (extended) position.

When valve1108is closed, water pressure is released via pressure outlet1118. Pressure outlet1118is a channel within stopper/strainer1102from which water can escape into plumbing. When enough water pressure1112is released from pressure outlet1118, spring1116retracts stopper/strainer1102into the original open position. Those skilled in the art will recognize that air pressure may be provided in place of water pressure to achieve the desired movement of stopper/strainer1102.

Alternately, the drain systems ofFIGS. 10 and 11may contain more than one stopper/strainer. For example, a system may contain one stopper and one strainer or a course strainer and a fine strainer (and optionally a stopper). Configurations incorporating multiple electrical circuits and controllers and/or multiple water lines and valves may be used to accommodate a plurality of stoppers/strainers.

FIGS. 12 and 13show exemplary plan side views of a drain system1200including a butterfly valve, ball valve or other quarter turn valve operated by a plunger1202. As shown, the quarter turn valve is a butterfly valve1203including a cylindrical body1204disposed flush to a wall of a drain stem1210; a disk1206rotatable about a rod (not shown) disposed through a diameter of the disk; and an actuator1208configured to control rotation of disk1206(via the rod). Actuator1208is attached to a rigid, pivotable connector1212that joins with a proximal end1214of plunger1202. Plunger1202is disposed, for example, with a faucet1216above a basin1218.

In an example of operation, butterfly valve1203is open, i.e., disk1206is vertically positioned (as shown inFIG. 12) so that water can flow from basin1218into drain stem1210, when plunger1202is pressed downward. When plunger1202is pulled upward, connector1212urges actuator1208to rotate a quarter turn (90 degrees), which rotates disk1206to a horizontal position (as shown inFIG. 13), and water is prevented from entering drain stem1210. Butterfly valve1203may be re-opened by pressing plunger1202downward to reverse the rotation of actuator1208.

FIG. 14shows an exemplary cross-sectional side view of a drain system1400including a ball valve, butterfly valve or other quarter turn valve1402disposed within a drain1401attached to a basin1403. Operation of ball valve1402is controlled by water pressure1404, where water may, for example, be diverted from flow within a main plumbing line (not shown). Valve1406may be opened and closed by pulling valve1406upward or pushing valve1406downward into base1414, respectively. When valve1406is closed, water bypasses and does not enter drain system1400. When valve1406is opened, water from the main plumbing line passes through an L-shaped duct1408within valve1406to tubing1410or1412, depending upon the rotation of valve1406.

Water from tubing1410or1412then enters a housing1416or1418. Housings1416and1418each contain a directional vane1420or1422, respectively. Directional vanes1420and1422are attached to ball valve1402at opposite points of an axis (shown as line14-14) that bisects a midpoint of conduit1424. Directional vanes1420and1422each have an arm1426,1428that causes rotation of ball valve1402in response to the direction of water flow within housing1416or1418. Arms1426and1428are offset 90 degrees relative to one another in order to provide proper opening and closing of ball valve1402. For example, when water enters housing1416, it forces arm1426upward and conduit1424of ball valve1402becomes aligned with a longitudinal axis of drain1401so that water may exit basin1403via conduit1424(seeFIG. 15showing an open configuration, as viewed along line14-14). On the other hand, when water enters housing1418, it forces arm1428downward and conduit1424of ball valve1402becomes aligned perpendicular to the longitudinal axis of drain1401so that basin1403becomes plugged (seeFIG. 16showing a closed configuration, as viewed along line14-14). Housings1416and1418are attached to a pressure relief valve1430which provides for passage of water into drain1401via inlet1432.

Those skilled in the art will appreciate that changes may be made to drain system1400. For example, ball valve1402may be biased in an open position, e.g., by one or more springs, and only one directional vane1420,1422may be present. In another example, ball valve1402may be biased in an open position, e.g., by one or more springs, until a valve (similar to valve1406) containing a T-duct is opened. Water from tubes1410and1412may then act in concert on directional vanes1420and1422to promote closing of ball valve1402.