Trap assembly for a hybrid wall urinal and associated methods

A trap for positioning within a wall urinal includes a housing having an open top end and an open bottom end coupled to a drainage pipe. The trap includes a top that includes an upper surface with a center portion having at least one drainage opening extending therethrough. The top is to be coupled to the open top end of the housing. A drainage tube has an open top end and an open bottom end, with the open top end coupled to the center portion of the top and aligned with the at least one drainage opening. A cup is to be suspended within the housing and has an open top end and a closed bottom end with sidewalls therebetween, and with the open bottom end of the drainage tube inserted into the cup.

FIELD OF THE INVENTION

The present invention relates to the field of urinals, and more particularly, to a trap for a wall urinal.

BACKGROUND OF THE INVENTION

Global demand on clean potable water continues to grow. Already strained water resources continue to fall in volume and quality. Additionally, waste water systems are finding difficulties with additional capacity due to population growth. As water conservation continues to increase in importance globally, waterless urinals will play an increasingly important role in conservation efforts.

Plumbing and sanitation codes require urinals to provide a liquid seal to prevent sewer gases from escaping. This has been achieved for many years by the use of conventional traps called p-traps, s-traps or bell traps. These typically form a seal by allowing residual flushing water to remain in sufficient quantity to provide the required barrier. This seal provides an effective method of blocking odors from entering the restroom environment. However, flushing systems allow residual urine to sometimes remain in the trap and not completely evacuate the trap of the urine. This causes the residual urine to break down and release ammonia dioxide in sufficient amounts to cause odors in the restroom. The upward facing surface of the trap communicates freely with the open environment causing odors. This is usually remedied by flushing the urinal multiple times to reduce the odors. This is a waste of clean fresh water.

Waterless urinals have now been widely accepted in the U.S. and across the world. Many of these use a trap covered with a lighter than water liquid, typically an oil based product. These typically use either a cartridge trap as disclosed in U.S. Pat. No. 5,711,037, a divided portion bell trap as disclosed in U.S. Pat. No. 7,636,957 or p-traps filled with oil. There is also a waterless self-flushing urinal that recycles and separates as disclosed in U.S. Pat. No. 7,111,332. Additionally, U.S. Pat. No. 7,246,386 discloses a waste outlet assembly using an elongated cylindrical insert with the lower end which ends in a reservoir of urine, which is the trap. The cylindrical insert sits slightly inside the waste trap.

The above mentioned traps are directly connected to the drain system, and are large in volume. These traps may also have removable bottom portion. There are also waterless urinals that are designed with one-way valves that allow urine to flow through while preventing sewer gases from coming back up through the valve.

The current waterless urinal systems, regardless of the different types, have deficiencies in terms of ongoing maintenance requirements, replacement of trap sealing media and drain line sediment buildup.

SUMMARY OF THE INVENTION

In view of the foregoing, an object of the present invention is to provide a straightforward trap assembly for wall urinals.

This and other objects, advantages and features are provided by a trap for positioning within a wall urinal comprising a housing having an open top end and an open bottom end coupled to a drainage pipe. The trap may comprise a top comprising an upper surface with a center portion having at least one drainage opening extending therethrough. The top may be coupled to the open top end of the housing. A drainage tube may have an open top end and an open bottom end, with the open top end coupled to the center portion of the top and aligned with the at least one drainage opening. A cup may be suspended within the housing and have an open top end and a closed bottom end with sidewalls therebetween, and with the open bottom end of the drainage tube inserted into the cup.

The cup may comprise a plurality of spaced apart ribs extending outwards from the sidewalls and contacting sidewalls of the housing.

The top may comprise a center mast extending outwards from the upper surface. The trap may further comprise an enclosure coupled to the center mast, and has a hollow interior for holding a gel material that reacts with urine received by said top.

The enclosure may comprise a bottom having a plurality of openings extending therethrough to expose the gel material to the urine, and a dome-shaped surface may be coupled to the bottom. The bottom may comprise a center hub extending outwards therefrom for receiving the center mast, with the bottom being spaced away from the upper surface of the top. The dome-shaped surface may comprise a notched edge extending past the bottom for contacting the upper surface of the top.

The trap may further comprise a removal tool comprising a shaft having a top end and a bottom end, and a pair of curved arms extending outwards from the bottom end of the shaft, with each arm comprising a lip for extending between notches of the notched edge of the dome-shaped cover. The top may comprise a center mast extending outwards from the upper surface, and wherein the top end of the shaft has an opening for engaging the center mast.

Another aspect is directed to a trap assembly comprising the housing and the trap received by the housing.

Yet another aspect is directed to a method for making a trap as described above.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially toFIGS. 1-3, a trap assembly10for a wall urinal20will now be discussed. The wall urinal20may be configured as a hybrid wall urinal, which means that it may be designed to operate as a waterless urinal, a water urinal, or both.

A flush valve assembly22is located at the top of the wall urinal20, as shown inFIGS. 1 and 2. When the flush valve assembly22is activated, water flows out of a plurality of openings24. For a waterless urinal, the flush valve assembly22would not be installed.

The illustrated wall urinal20is much like a standard urinal bowl except for the bottom. The bottom of the bowl has an opening26for receiving the trap assembly10, where an exploded view is provided inFIG. 3. As will be described in greater detail below, the trap assembly10functions optimally with or without water.

The trap assembly10includes a housing40and a trap50that is received by the housing. The housing40is to be positioned within the opening26of the wall urinal20. The housing40has an open top end42and an open bottom end44to be coupled to a drainage pipe28.

The trap50includes a top52that has an upper surface54with a center portion56having at least one drainage opening58extending therethrough. The top52is coupled to the open top end42of the housing40. A drainage tube60has an open top end62and an open bottom end64. The open top end62is coupled to the center portion56of the top52and is aligned with the at least one drainage opening58. A cup70is suspended within the housing40and has an open top end72and a closed bottom end74with sidewalls76therebetween. The open bottom end64of the drainage tube60is inserted into the cup70.

The cup70includes a plurality of spaced apart ribs78extending outwards from the sidewalls76thereof and contacts the housing40. The spacing between the sidewalls76of the cup and interior sidewalls of the housing define an overflow drainage, the contents of which are received by the drainage pipe28.

The top52includes a center mast59extending outwards from the center portion56. An enclosure80is coupled to the center mast59, and has a hollow interior for holding a gel material82that reacts with urine received by the top52. The enclosure includes a bottom84having a plurality of openings86extending therethrough to expose the gel material to the urine. A dome-shaped surface88forming the hollow interior is coupled to the bottom84.

The bottom84includes a center hub89extending outwards therefrom for receiving the center mast59. The interface between the center mast59and the hub89may be threaded, for example. The bottom84is spaced from the upper surface54of the top52. The dome-shaped surface88includes a corrugated or notched edge90extending past the bottom84for contacting the upper surface54of the top52. The notched edge90includes a series of spaced apart notches91around the perimeter of the dome-shaped surface88to prevent debris from blocking the drainage openings58in the center portion56of the top52.

A removal tool100may also be provided for removing the enclosure80when coupled to the center mast59. The removal tool100may also be used for coupling the enclosure80to the center mast59. Yet another use for the removal tool is to remove the trap50from the housing40.

The removal tool100includes a shaft102having a top end104and a bottom end106, and a pair of curved arms108extending outwards from the bottom end106of the shaft102. Each arm includes a lip110for extending between adjacent notches91on the dome-shaped cover88. This is useful for holding the enclosure80so that it may be secured to the center mast59by rotating in a clockwise direction, or removed from the center mast59by rotating in a counter-clockwise direction when the interface between the center mast59and the center hub89is a threaded interface. Each arm108may also have a tab109extending therefrom so as to allow a user to pull on so as release the enclosure80(and the trap50if coupled to the enclosure) from the engaged lips110.

In addition, the top end104of the shaft102has an opening for engaging the center mast59. The interface between the center mast59and the top end104of the shaft102may also be a threaded interface. With the top end104of the shaft102secured to the center mast59, the trap50may be removed from the housing40, as well as inserted into the housing40as needed.

The housing40may be configured with the open bottom end44extending outwards in a vertical direction, as shown inFIG. 3. Alternatively, the open bottom end44′ may extend in a horizontal direction, as shown inFIG. 4. Inserts associated with the housing40′ will now be discussed in reference toFIG. 4.

A plate120′ may be secured to the housing44′. An outer edge of the plate120′ has a plurality of spaced apart recessed openings122′ configured to receive fasteners used to create a downward pressure on the housing40′. This downward pressure effectively locks the housing40′ to the urinal20so that a secure connection may be made. One or more stainless steel rings124′,126′ may be inserted into an opening in the plate120′. A gasket128′ may be positioned between the plate120′ and the stainless steel rings124′,126′.

Adapters and couplers, collectively indicated by reference130, may be used to interface between the open bottom end44′ of the housing40′ to the drainage pipe28, as shown inFIG. 5.

A top perspective view of the housing40′ with the inserts120′,124′ and126′ positioned therein is shown inFIG. 6. A side cut-away view of the housing40′ positioned within an opening26′ of a wall urinal20′ is shown inFIG. 7. The illustrated housing40′ also includes the inserts120′,124′ and126′ positioned therein. Similarly, a side cut-away view of the housing40′ and trap50positioned within an opening26′ of a wall urinal20′ is shown inFIG. 8. The illustrated housing40′ and trap50′ also includes the inserts120′,124′ and126′ positioned therein.

Referring now toFIG. 9and back toFIG. 3, specifics of the trap assembly10including operation thereof will now be discussed in greater detail. The center mast59of the top52is about 1 cm in length and the drainage openings58in the center portion89of the top52allows for drainage into the tube60. The tube60is cylindrical in shape with a wide top that may be glued to a bottom surface of the top52. The tube60is inserted inside the cup about ¾ of the way inside.

The illustrated cup70has3ribs78which attach to the housing40with locking clips having a u-shaped opening to receiving outer edges of a respective rib78. The ribs78may be glued within the locking clips. The housing40may be joined to the top52utilizing3locking clips. These locking clips may also be glued around the outer circumference on the outside of the housing40where joined with the top52.

The housing40has an open bottom end42defining a drain area with a tubular drain assembly130that may be coupled thereto. An o-ring45is positioned on the open bottom end of the housing40to create a sealed connection with the tubular drain assembly130.

In addition, the top52has two groves55to accommodate two sealing rubber gaskets57. The sealing rubber gaskets57provide a tight seal against the stainless steel retainer ring126′ shown inFIG. 4that is attached to be attached to the housing40.

The trap50allows urine to flow through the top52, as indicated by arrows130, with the urine creating a liquid seal. The trap50is design so that the urine itself provides a necessary liquid seal to maintain proper protection against sewer gases. The tube60may have an internal diameter of 17 mm, for example, to create a very small surface area which limits exposure to potential urine odor. This is due not only to the diameter of the tube60exposed but also to the liquid amount in total within the cup70. In total volume the trap holds about 4 liquid ounces.

The average male urinates about 12 liquid ounces. This amount is more than sufficient to completely change the contents of the cup70, as indicated by arrows140representing the flow of urine through the tube60and through the cup70. As urine exits the body it has a ph between 6.5 to 7.2 normally. When the urine enters the trap assembly10it will by gravity and design, so that the urine concentrates around the center mast59of the top52.

The center mast59is attached directly above to the enclosure80, which is gel82filled. The enclosure80has an exposed bottom84. The exposed bottom84will come in contact with the urine. The gel82has Ph lowering capabilities as it is made with citric acid having a ph of 4. The gel82also has enzymatic material designed to digest urea sediment. In addition, the gel82has fragrance to reduce foul odors. The combination of the size of the tube60, which defines a surface area exposure size of the urine, the reduced overall cup70size, which provides about a 2 inch liquid seal, and the enclosure80advantageously offer protection against foul odors.

More generally, the trap assembly10allows the customer to choose how to operate and maintain their wall urinal20. A hybrid urinal20thus allows the customer to customize whether the urinal will operate as a waterless urinal, a water urinal, or both.

The trap assembly10accepts traditional flush valve assemblies with manual or automatic actuation. The flush valve (if desired) can be manual. However, manual valves will have push button manual flushing mechanism installed on the back while not allowing the user to flush. Only the maintenance personnel should have knowledge to flush the system when it is deemed necessary. This will allow easy access for maintenance personnel to a water source and which will facilitate the periodic flushing of the system. This will have no negative effect on the trap50and will actually be recommended to keep drain lines free and clear of debris.

Another option is an electronic flush valve version. The electronic flush valve has a programmable circuit board that will electronically activate flushing action similarly to other electronic type valves. An optical infrared sensor device may be used to accurately measure and count users as they are in front of the wall urinal20at a minimum of 5 seconds, for example. This will not trigger automatically generate a flushing action since user may be counted. The circuit board will have programmable option action switches that will be controllable by the customer. This controllable feature will allow the installer to program the wall urinal20system to flush after every 25, 50, 75 or 100 users have visited the urinal, for example. This will automatically clean the trap50and flush enough water to clean the drain line to prevent any residual drain line clogging issues.

A variation of this technique is to offer a program sentinel flush. The sentinel flush is a program by which the flush valve will automatically flush a full 1.5 gallon flush every 24 hours. This will offer the same benefits as previously mentioned. Another option is to conventionally install either a manual or an automatic valve that will flush only 12 ounces of water per flush. This will completely evacuate the trap50of any residual urine. This option basically makes the system an ultra low flow water urinal.

The trap assembly10advantageously utilizes the trap50to optimally insure viability of waterless urinals while reducing maintenance and eliminating sediment buildup issues associated with other waterless urinal systems.

Referring now to the flowchart150in FIG. Another aspect is directed to a method for making a trap50for positioning within a wall urinal20comprising a housing40having an open top end42and an open bottom end44coupled to a drainage pipe28. From the start (Block152), the method comprises providing at Block154a top52comprising an upper surface54with a center portion56having at least one drainage opening58extending therethrough, with the top52to be coupled to the open top end42of the housing40. A drainage tube60is provided at Block156, where the drainage tube has having an open top end62and an open bottom end64, with the open top end being coupled to the center portion56of the top52and aligned with the at least one drainage opening58. A cup70is provided at Block158to be suspended within the housing40and has an open top end72and a closed bottom end74with sidewalls76therebetween, and with the open bottom end64of the drainage tube60inserted into the cup70. The method ends at Block160.