Adjustable drain assembly

An adjustable drain assembly is provided. The assembly includes a base that has a concave inner pivoting surface and a top surface. An upper member is present and has a bottom surface located above the top surface. The upper member may have a concave inner pivoting surface. A pivot component may be present and have a convex outer pivoting surface that engages the concave inner pivoting surface of the base and upper member. The pivot component may be configured for engagement with a cover member. The base may have a pipe engagement surface for engagement with a pipe that is located completely below the pivot component.

FIELD OF THE INVENTION

The present invention relates generally to an adjustable drain assembly. More particularly, the present application involves an adjustable drain assembly for use with waste water removal that can be adjusted so as to be flush with an upper surface of a floor for better drainage, appearance, and safety.

BACKGROUND

Floor drains are commonly found in locations such as bathrooms, basements, and showers for use in removing water that is either intentionally or unintentionally placed onto the surface that includes the floor drain. The drain generally includes a grate through which water and waste flows. An assembly attached to the grate is located below the floor and is itself attached to a pipe. The water and waste can flow through the grate and assembly and into the pipe for subsequent removal.

Plumbing codes generally require the pipe to be positioned at a certain angle so that water within the pipe may flow in the desired direction via gravity. The pipe usually takes the shape of an elbow at the drain location and placement of the pipe at the necessary angle thus causes the upper end of the pipe to be positioned at the same angle. Subsequent attachment of the grate and associated assembly to the pipe may cause the grate to be situated at an angle to the surface of the floor. A portion of the grate and/or assembly holding the grate may stick up from the surface of the floor or be located beneath the surface of the floor. Aside from creating an eyesore, this arrangement may present a tripping hazard to the occupants of the space or can cause damage by being snagged against shoes or socks.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

The present invention provides for an adjustable drain assembly10that can be used to align a grate84of a cover member80with the upper surface88of a concrete floor86to result in a safer and more visually pleasing arrangement. The adjustable drain assembly10may include a pivot component60housed within a base12and an upper member40. The pivot component60may have a convex outer pivoting surface62that engages concave inner pivoting surfaces18and42of the base12and upper member40to allow the pivot component60to pivot with respect to the base12and upper member40. The pivot component60can be adjusted so that the cover member80and grate84are moved to a desired position. A locking force may then be applied to the base12and upper member40to lock the position of the pivot component60, and hence cover member80and grate84, with respect to the base12and upper member40.

FIG. 1illustrates one exemplary embodiment of the adjustable drain assembly10shown in relation to a concrete floor86. Installation of a drain into a floor of a residence or building may involve the placement of a pipe90at an angle to an upper surface88of a concrete floor86of the building. The pipe90may be placed at such an angle in order to ensure the flow of water through the pipe90for disposal. The adjustable drain assembly10facilitates an even placement of the cover member80with respect to the concrete floor86by including components that may be angled to one another. The pipe90may be rigidly connected to the bottom of a base12. A pivot component60can be locked onto the base12and angled thereto. As shown, an axis94passing through the center of the base12is oriented at an angle to an axis96passing through the center of the pivot component60. The cover member80can be attached to the pivot component60and can be properly positioned so that a grate84of the cover member80lays flush with the upper surface88of the concrete floor86.

An alternative exemplary embodiment of the adjustable drain assembly10is shown inFIG. 2. The drain assembly10includes a base12, upper member40, and pivot component60. A cover member80can be attached to the pivot component60. With reference now toFIGS. 2,5and6, the base12defines a through bore26from a top surface14to a bottom surface16. A concave inner pivoting surface18can extend from the top surface14and may define a portion of the through bore26. The concave inner pivoting surface18can have a constant radius of curvature or may have a varying radius of curvature along its length. The concave inner pivoting surface18may be arranged so that the diameter of the portion of the through bore26formed by the concave inner pivoting surface18decreases in the direction extending away from the top surface14and at no point increases or remains the same along the entire length of the concave inner pivoting surface18. The concave inner pivoting surface18may terminate at an upper step20that can extend in a direction perpendicular to an axis94extending through the base12.

The base12may also include a pipe engagement surface28that can extend from the bottom surface16. In some arrangements, the pipe engagement surface28may be located on the inside of the base12and form a portion of the through bore26. In other embodiments, the pipe engagement surface28may be located along a portion of the outer side wall36of the base12. In still other arrangements, the pipe engagement surface28may be located at the bottom surface16and need not extend along the inner wall or outer side wall36of the base12. The pipe engagement surface28may be provided for engagement with the pipe90, although it is to be understood that portions of the pipe engagement surface28need not contact the pipe90when the pipe90is attached to the base12. However, in other arrangements, the entire pipe engagement surface28contacts the pipe90when the pipe90is attached to the base12.

In the embodiment illustrated, the pipe engagement surface28extends from the bottom surface16and defines a portion of the through bore26that has a constant diameter. The pipe engagement surface28terminates at a lower step24that extends towards the axis94and causes the diameter of the through bore26to be reduced in size at the lower step24. An inner surface22may extend from the lower step24to the upper step20and can be arranged so that it does not extend towards or away from the axis94and maintains the through bore26at a constant diameter. A flushing aperture34can extend from the outer side wall36of the base12to the through bore26. The flushing aperture34can penetrate the outer side wall36at the inner surface22so as to extend through the inner surface22. The flushing aperture34may be present in order to introduce water or other fluid into the drain assembly10and/or pipe90. Non-use of the drain may result in water present within the drain to dry up, thus allowing sewage gases from the sewer system to revert back through the drain and into the building to which the drain is installed. Water may be inserted through the flushing aperture34to maintain a sufficient water level in a trap used to act as a buffer to sewage gases. However, it is to be understood that other arrangements of the adjustable drain assembly10may be provided that do not include a flushing aperture34. Further, the flushing aperture34may be provided at a different location of the adjustable drain assembly10in other embodiments. In applications that do not involve water removal, a plug (not shown) may be inserted into the flushing aperture34to close off this opening if desired. Also, in applications involving the removal of waste water, the flushing aperture34can be unused if so desired and can be either closed off or left open.

The diameter of the through bore26may thus be varied along the length of the through bore26from the top surface14to the bottom surface16. In other arrangements, the through bore26may be formed completely by the concave inner pivoting surface18and the other portions of the base12forming the through bore26as illustrated need not be present. In these arrangements, the through bore26may have a completely varying diameter along its entire length. The pipe90may be arranged so that it is completely below certain portions of the adjustable drain assembly10such as the pivot component60, upper member40, and the cover member40. As such, no portion of the pivot component60may be capable of being inserted into the pipe90so as to be located within a through bore of the pipe90. The attached adjustable drain assembly10forms an opening through which water or other waste material may flow through a grate84and through the interior of the adjustable drain assembly10and into the interior of the pipe90and then transported to a desired location. It is to be understood, however, that other arrangements are possible in which one or more of the components of the adjustable drain assembly10such as the pivot component60, upper member40, and/or cover member80are capable of being inserted into the pipe90. As such, other arrangements are possible in which one or more of the components are not located completely above the pipe90. In still other arrangements, the adjustable drain assembly10may be made so that the various components can touch the drain90but not be located within the drain90.

FIG. 12illustrates an alternative exemplary embodiment of the adjustable drain assembly10in which the base12includes a pipe engagement surface28that extends from the bottom surface16. A portion of the through bore26is defined by the concave inner pivoting surface18that ends at an upper step20that extends in a direction perpendicular to the axis94of the base12. The concave inner pivoting surface18and the upper step20may be arranged as previously described. The pipe engagement surface28defines a portion of the through bore26from the bottom surface16to the upper step20such that this portion of the through bore26has a constant diameter. As such, the lower step24and the inner surface22of the previously described embodiment are not present. The pipe90may be attached to the base12and can engage the entire length of the pipe engagement surface28or may engage only a portion of the length of the pipe engagement surface28.

With reference now back toFIGS. 2,5and6, the portion of the base12that defines the concave inner pivoting surface18may be integrally formed with the portion of the base12that defines the pipe engagement surface28so that these portions are a single piece. In this manner, the base12can be a single piece and not multiple pieces formed together that form the concave inner pivoting surface18and the pipe engagement surface28. The portions of the base12as shown in the figures may be a single, integrally formed piece. However, other arrangements may exist in which multiple separate pieces are combined together so as to form the concave inner pivoting surface18and the pipe engagement surface28of the base12.

The base12may include one or more flanges30positioned an equal distance about the perimeter of the base12. Any number of flanges30may be included. For example from 1-3, from 2-5, or up to 10 flanges30may be present in other arrangements. As illustrated, three flanges12are present and each includes a flange aperture32extending therethrough. The flanges30and flange apertures32are used for engagement with an upper member40so that a locking bolt92can be disposed therethrough for use in providing a locking force to the adjustable drain assembly10. However, other embodiments are possible in which flanges30and locking bolts92are not used to generate a locking force of the adjustable drain assembly10. For example, set screws, a friction fit, mechanical fasteners, or interlocking components can be used to effect locking of the adjustable drain assembly10.

Referring now toFIGS. 2,9and10, the adjustable drain assembly10includes an upper member40that has a bottom surface44that may directly face the top surface14of the base12. The bottom surface44may be spaced from the top surface14or may in fact engage the top surface14in certain arrangements. The top surface14and bottom surface44may both be flat surfaces or may be variously shaped in other arrangements. The upper member40may include one or more flanges46that can coincide with the flanges30of the base12. Any number of flanges46may be present in various arrangements such as from 1-3, from 2-5, or up to 10 flanges. The flanges46can each include a flange aperture48that align with respective flange apertures32of the flanges30. A locking bolt92can be disposed through both the flange aperture32and the flange aperture48and tightened in order to urge the top surface14of the base12and the bottom surface44of the upper member40towards one another so as to effect locking of the adjustable drain assembly10. As previously discussed, the use of flanges46and locking bolts92need not be present in other arrangements in order to effect locking of the adjustable drain assembly10.

The upper member40defines a through bore50that extends from a top surface52to the bottom surface44. The upper member40also has a concave inner pivoting surface42that may define the entire through bore50. In other arrangements, the concave inner pivoting surface42may define only a portion of the through bore50and other portions of the upper member40can define the rest of the through bore50. The concave inner pivoting surface42can be arranged so that the through bore50increases in diameter along the entire length of the through bore50from the top surface52to the bottom surface44. In this regard, the concave inner pivoting surface42constantly changes along its entire length so that the through bore50does not have a constant diameter at any location. The radius of curvature of the concave inner pivoting surface42may be constant along its entire length, or various radii of curvature of the concave inner pivoting surface42may exist along its length. Further, the radius of curvature of the concave inner pivoting surface42may be the same as, or different from, the radius of curvature of the concave inner pivoting surface18of the base12.

The upper member40can have a top surface52that is convex in shape. The top surface52can be differently shaped than the bottom surface44, or may be the same shape as the bottom surface44in other embodiments. The top surface52can be arranged so that the upper member40cannot be flipped upside down so to make the top surface52directly face the top surface14of the base12. However, other arrangements are possible in which the upper member40may be capable of being flipped upside down so as to face the top surface14. For example, the top surface52need not be convex in shape but can have flat sections that extend around the entire circumference. In these alternate embodiments, the top surface52generally forms an apex in which a portion of the top surface52extends away from the concave inner pivoting surface42. In other arrangements, the top surface52may be flat.

With reference now toFIGS. 2,7and8, the adjusting drain assembly10includes a pivot component60that has a convex outer pivoting surface62. A number of recesses64are defined in the convex outer pivoting surface62and extend generally along the length of the pivot component60so as to be roughly aligned with the axis96of the pivot component60. The convex outer pivoting surface62may have a single, constant radius of curvature or may have varying radii of curvature in other exemplary embodiments. The radius of curvature of the convex outer pivoting surface62may be the same as the radii of curvature of the concave inner pivoting surfaces18and42. As such, the convex outer pivoting surface62may be complimentary to the concave inner pivoting surfaces18and42so as to be capable of engaging these surfaces18and42. The user may adjust the position of the pivot component60with respect to the upper member40and the base12. The geometry of the pivot component60may function to limit the range of adjustment of the pivot component60. For example, the portion of the pivot component60at the bottom of the convex outer pivoting surface62may extend inwards towards the axis96and may abut against the upper step20so as to prevent further pivoting of the pivot component60. This may be illustrated with reference back toFIG. 1in which the pivot component60abuts against the upper step20. Also, as illustrated with reference toFIG. 1, the pivot component60need not have any recesses64located thereon. Although shown as extending completely around the axis94of the pivot component60, in other arrangements the recesses64may extend up to 90°, up to 180°, or up to 270° around the convex outer pivoting surface62of the pivot component60. The recesses64may function to reduce the weight of the pivot component60and hence reduce the cost of material in manufacturing this portion of the adjustable drain assembly10.

Referring back toFIGS. 2,7and8, the convex outer pivoting surface62extends completely around the outer circumference of the pivot component60. In other arrangements, the convex outer pivoting surface62need not extend completely around the entire outer surface of the pivot component60. In this regard, a portion of the outer surface of the pivot component60need not be convex in shape. The convex outer pivoting surface62may engage the concave inner pivoting surfaces18and42but can slide across these surfaces so that the angle of the axis96of the pivot component60can be adjusted relative to the axis94of the aligned base12and upper member40. The engagement may also allow for the pivot component60to be able to be spun around on its axis96a complete 360°. Once the pivot component60has been oriented to a desired position relative to the base12and the upper member40, the locking bolts92can be tightened in order to exert a force urging the base12and the upper member40towards one another. This force will be translated to the concave inner pivoting surfaces18and42that will be moved against the convex outer pivoting surface62in order to pin the convex outer pivoting surface62into the desired position. Repeated tightening of the locking bolts92will cause the convex outer pivoting surface62to be tightly engaged between the concave inner pivoting surfaces28and42and held securely into position.

The convex outer pivoting surface62extends from the top surface72of the pivot component60and terminates at a location above the bottom surface68so as not to extend all the way to the bottom surface68. In other arrangements, the convex outer pivoting surface62can extend upwards from the bottom surface68and terminate at a location short of the top surface72. In yet other exemplary embodiments, the convex outer pivoting surface62may extend the entire length from the top surface72to the bottom surface68. The pivot component60defines a through bore78that extends from the top surface72to the bottom surface68. A first inner surface70can extend from the top surface72and may form a portion of the through bore78. The first inner surface70may have internal threading66defined thereon and, with the exception of the internal threading66, can form a portion of the through bore78that has a constant diameter. A sloped surface76can extend from the bottom of the first inner surface70and may be directed so as to cause the portion of the through bore78formed by the sloped surface76to decrease in diameter in the direction extending away from the first inner surface70along the axis96. The sloped surface76may have a constant degree of slope or may have various degrees in different embodiments. A second inner surface74may be defined from the bottom of the sloped surface76to the bottom surface68and can form a portion of the through bore78that has a constant diameter. The bottom surface68may be located in the portion of the through bore26formed by the inner surface22of the base12. In other arrangements when pivoted, the bottom surface68may be located in the portions of the through bore26formed by both the inner surface22and the concave inner pivoting surface18of the base12. For example, in an alternative arrangement of the adjustable drain assembly10the pivot component60includes a through bore78defined by a first inner surface70and a sloped surface76that extends from a top surface72to a bottom surface68. The slope surface76can be arranged so that it extends from the bottom surface68to the first inner surface70, and a second inner surface74need not be present.

Referring back toFIGS. 2,7and8, the pivot component60may be arranged so that the pivot component60is located along the entire length of the through bore50of the upper member40. Further, the pivot component60may extend along a portion of the length of the through bore26of the base12. In other embodiments, the pivot component60may extend along the entire length of the through bore26of the base12and may extend along the entire length of the through bore26of the base12. In yet further arrangements, the pivot component60may be located in and extend along the entire length of the through bore26of the base12, and the pivot component60may be located in and extend through only a portion of the through bore50of the upper member40and not through the entire length of the through bore50.

A cover member80can be attached to the pivot component60and can have an axis that aligns with the axis96of the pivot component60so that positioning of the pivot component60effects positioning of the cover member80. The cover member80can be a separately purchased component or may be supplied with and form a part of the adjustable drain assembly10upon purchase. The cover member80may include a through bore and have external threading82that engages the complimentary internal threading66of the pivot component60so as to effect attachment. A grate84may be located at the top of the cover member80. The user may turn the cover member80to move the cover member80due to the treaded connection between the cover member80and the pivot component60. The height of the grate84may thus be raised and lowered with respect to the pivot component60, upper member40, and base12. The cover member80illustrated in the exemplary embodiment includes a second set of threaded members that allows for additional adjustment of the height of the cover member80should the adjustments provided by the external threading82and internal threading66not be sufficient. The cover member80may be variously configured in accordance with different exemplary embodiments and a variety of types of cover members can be attached to the adjustable drain assembly10. The cover member80may be a clean out or a cover plate in accordance with different exemplary embodiments.

One exemplary embodiment of the installation of the adjustable drain assembly10may first include the installation of the pipe90out of the ground at a desired drainage pitch angle. A string line may be placed that represents the final level of a cement floor86that is to be subsequently poured. The installer may place the adjustable drain assembly10onto the top of the pipe90and install same thereon. For example, the top of the pipe90may be press fit onto the pipe engagement surface28. Other arrangements are possible in which the engagement between the pipe90and the base12may be effected through a threaded engagement, mechanical fasteners, or snap-in locking. Plumber's tape may be used to ensure this connection remains leak proof if desired. The installer can then adjust the angular orientation of the pivot component60and attached cover member80so that a grate84of the cover member80is level with the string line. The height of the cover member80with respect to the pivot component60can be adjusted as needed through the threaded engagement between internal threading66and external threading82so that the grate84is located at the sting line. Once the installer is satisfied with the position of the grate84, he or she may tighten the locking bolts92so as to lock the angular orientation of the grate84and attached cover member80and pivot component60. A water line may be attached to the flushing aperture34either before or after positioning of the grate84is accomplished.

The concrete slab may be poured around the adjustable drain assembly10in order to form the concrete floor86. The rigid interlocking of the adjustable drain assembly10will prevent this component and the attached grate84from being moved out of position when subjected to forces applied by the cement.FIG. 3illustrates one exemplary embodiment in which recesses64are located on the pivot component60. Concrete may enter the recesses64when poured to form the concrete floor86. Hardening of concrete within the recesses64may further function to more securely anchor the adjustable drain assembly10into the concrete floor86.

With reference now to the exemplary embodiment ofFIG. 1, the adjustable drain assembly10is shown in relation to a concrete floor86. As shown, the pivot component60, cover member80, and the grate84are pivoted in relation to the pipe90, base12and upper member40so that the top of the grate84is flush with the upper surface88of the concrete floor86. This positioning may eliminate the grate84or other portion of the cover member80as a tripping hazard since they are not flush with the upper surface88. Also, this arrangement may prevent the accumulation of water or debris and resultant bacteria that will now go down the drain instead of being located outside of or at the grate84due to its positioning. Further, the arrangement may function to stabilize the line connected to the flushing aperture34as it may likewise be encased in concrete. The exemplary embodiment ofFIG. 1does not include recesses64. However, the adjustable drain assembly10may still be securely held within the concrete floor86by having the concrete poured around the various components of the adjustable drain assembly10. Further, although shown and described as being used in conjunction with a concrete floor86, the adjustable drain assembly10may be used with other types of floors such as wood floors in accordance with other exemplary embodiments. Also, although described as being used in connection with water in a plumbing application, the adjustable drain assembly10may be used in other applications. For instance, the adjustable drain assembly10may be used in conjunction with an electrical conduit for use in housing electrical components such as wire or cable.