Sump drain apparatus, system, and method of construction

The present disclosure provides a sump drain apparatus comprising a drain inlet and a ramp coupled to the drain inlet comprising an incline plane configured to divert drainage water toward the drain bowl, wherein at least a portion of the ramp is configured to be positioned on top of a roof deck.

FIELD OF THE DISCLOSURE

The present disclosure relates to a water evacuation apparatus, system, and method of construction, and more specifically, to an insulated roof sump drain apparatus, system, and method of construction.

BACKGROUND OF THE DISCLOSURE

Conventional roofing systems typically include drainage systems configured to remove water on the roof resulting from precipitation. There are two basic types of drainage systems: perimeter evacuation systems in which water is transported to an edge of a roof prior to removal and internal evacuation systems in which water is transported to an isolated area on the roof prior to removal. Internal evacuation systems in particular may be prone to leaking due to the proximity of mating points between components near areas of high concentration of water.

SUMMARY OF THE DISCLOSURE

A sump drain apparatus may comprise a drain inlet (e.g., comprising an inlet conduit and/or a drain bowl) and a ramp connected to the drain bowl comprising an incline plane configured to divert drainage water toward the drain bowl. A sump drain may comprise an attachment portion (e.g., a fastener aperture, attachment flange, and/or the like), which may be configured to couple the sump drain apparatus to a roof deck. The ramp may be configured to be positioned on top of the roof deck. Sump insulation may be disposed beneath the ramp and above the roof deck. The attachment portion (e.g., an attachment flange) may be coupled to the ramp. In various embodiments, the attachment portion may be coupled to the ramp by an insulation receiving surface coupled to and extending downward from the ramp, between the ramp and attachment portion.

In various embodiments, the drain inlet, the ramp, insulation receiving surface, and/or the attachment portion may comprise a single, continuous structure. The drain inlet may be connected to the ramp directly, or with a first land spanning between the drain inlet and the ramp. In various embodiments, the attachment portion may be connected to the ramp directly, or with a second land and/or an insulation receiving surface spanning between the attachment portion and the ramp. In various embodiments, the attachment portion may be disposed in or through the ramp and/or the second land. The drain inlet may be connected to and/or continuous with an outlet conduit. The inlet conduit of the drain inlet may comprise an annular shape and may be configured to couple to a drain bowl strainer. The insulation receiving surface may be substantially perpendicular to the second land and/or attachment portion and positioned between the second land and attachment portion. The first land may comprise an upper surface and a lower surface, the lower surface configured to rest on the roof deck. The insulation receiving surface may be configured to couple to an insulation retention clip and abut roof insulation.

A sump drain system for a roof may comprise a sump drain apparatus comprising a drain inlet and/or a ramp connected to the drain inlet comprising an incline plane configured to divert drainage water toward the drain bowl. In various embodiments, a sump drain apparatus may comprise an attachment portion configured to couple the sump drain apparatus to a roof deck. The ramp may be configured to be positioned on top of the roof deck and contain sump insulation beneath the ramp and above the roof deck.

In various embodiments, the drain inlet and the ramp may comprise a single, continuous structure. The attachment portion may also be a single, continuous structure with the drain bowl and ramp. In various embodiments, the sump drain system may further comprise an insulation retention clip coupled to an insulation receiving surface of the sump drain apparatus. The sump drain system may further comprise a drain bowl strainer coupled to an inlet conduit of the sump drain apparatus. The sump drain apparatus may further comprise an outlet conduit connected to and/or continuous with the drain inlet. The sump drain system may further comprise a drain pipe coupled to the outlet conduit. The sump drain apparatus may further comprise a first land and a second land connected to and/or continuous with the ramp. The sump drain system may further comprise a roof membrane coupled to the second land, wherein the roof membrane is one of thermally coupled to, chemically coupled to, coupled to by way of adhesive, cured to, or welded to the second land.

A method of constructing roof sump drain system may comprise forming a hole in a roof deck, coupling a sump drain apparatus to the roof deck, coupling roof insulation to the roof deck and sump drain apparatus, and coupling a roof membrane to the sump drain apparatus over the roof insulation.

In various embodiments, the sump drain apparatus may comprise a drain inlet and a ramp connected to the drain inlet comprising an incline plane configured to divert drainage water toward the drain bowl. In various embodiments, the sump drain apparatus may comprise an attachment portion configured to couple the sump drain apparatus to a roof deck. The ramp may be configured to be positioned at least partially on top of the roof deck and contain sump insulation beneath the ramp and above the roof deck. The method may further comprise inserting the roof insulation beneath an insulation retention clip coupled to the sump drain apparatus.

DETAILED DESCRIPTION

The detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that logical, chemical, electrical, and mechanical changes may be made without departing from the spirit and scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation.

For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full, and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.

For example, in the context of the present disclosure, methods, systems, and articles may find particular use in connection with roofing drainage systems. However, various aspects of the disclosed embodiments may be adapted for performance in a variety of other drainage systems. As such, numerous applications of the present disclosure may be realized.

Various problems exist with known roofing drainage systems. For example, many contemporary drainage systems comprise many components of different materials coupled together to form the completed drainage system. Naturally, these components have different coefficients of thermal expansion, thereby expanding and contracting at different rates. Such differences in the expansion and contraction of components can lead to deterioration of the seal of the drainage system, thereby resulting in the intrusion of water past the drainage system into the underlying building.

Traditional drainage systems utilize three main components: a drain bowl, an insulated sump area, and a roof membrane. Typically, a hole is first cut into the deck of the roof which will receive the drain bowl. The drain bowl is then mechanically attached to the roof deck. An insulated sump area in the form of wedged insulation is installed directly onto the roof deck around the hole and configured to allow water to flow on a downward gradient towards the drain. The insulated sump is then covered by a waterproof membrane over the sump insulation and draped down into the hole onto the drain bowl. A compression ring is then inserted over the top of the membrane and fastened to the drain bowl or other components immediately adjacent to the hole using mechanical fasteners. Such an arrangement is intended to provide a waterproof route for drainage water from various portions of the roof to the drain.

Arrangements such as those described above may concentrate drainage water near the mating point of multiple components, thereby increasing a likelihood that water will move beyond its intended route and leak into the underlying building. Further, by placing the membrane near the drain, the membrane may tend to bow under the pressure of the compression ring, thereby potentially inhibiting water movement toward the drain and resulting in large areas of standing water around the drain. Overtime, this may result in structural failure of the roof or a potential collapse of the roof due to the weight of the standing water. Additionally, such systems may be costly to manufacture, require long installation times, and may be at a higher risk of being installed incorrectly.

Accordingly, with reference toFIG. 1, a perspective view of a sump drain frame100and drain bowl strainer200detached from sump drain frame100is illustrated, in accordance with various embodiments. Sump drain frame100may comprise a single-piece component configured to direct drainage water from surrounding areas of a roof to a drain placed at and/or near a center of sump drain frame100. In various embodiments, sump drain frame100may comprise any suitable material, for example a polymer, metal, ceramic, or composite material in accordance with various embodiments. More specifically, sump drain frame100may comprise a thermoplastic material such as a thermoplastic olefin (TPO), which may include polypropylene (PP), polyethylene (PE), or block copolymer polypropylene. In various embodiments, sump drain frame100may comprise a polyvinyl chloride material (PVC). Sump drain frame100material may comprise one or more fillers such as talc, fiberglass, carbon fiber, wollatonite, or metal oxy sulfate. Sump drain frame100may comprise an elastomer such as ethylene propylene diene terpolymer (EPDM), ethylene-octene, ethylbenzene, or styrene ethylene butadiene styrene. Any suitable manufacturing technique may be utilized to form sump drain frame100. For example, in accordance with various embodiments, sump drain frame100may be cast, forged, additively manufactured, molded through an injection molding or vacuum forming process, or any other suitable technique.

Referring now toFIG. 1-FIG. 3, sump drain frame100may form a portion of a sump drain system1000, in accordance with various embodiments. Sump drain frame100may comprise an outlet conduit102, a drain inlet (e.g., comprising a drain bowl104and/or an inlet conduit106), a first land108, a ramp110, a second land112, an insulation receiving surface114, and/or an attachment portion. Any combination, or all, of these components may make up a single, unitary, and/or monolithic component (the sump drain frame), which does not have any seams or cracks between the components.

Outlet conduit102may comprise any suitable shape, such as an annular inner surface118and an annular outer surface120. Annular inner surface118may be configured to contain drainage water and transfer drainage water downward (in the negative Y-direction) to a drain pipe122situated below outlet conduit102. The outlet conduit may be coupled to a drain pipe. For example, annular outer surface120may be configured to couple sump drain frame100to drain pipe122using a coupling such as a no-hub connector or other suitable device208. For example, in various embodiments, sump drain frame100may be aligned with drain pipe122such that outlet conduit102substantially aligns with drain pipe122. A no-hub connector may be inserted over a mating point between outlet conduit102and drain pipe122and tightened to secure sump drain frame100to drain pipe122. In such a way, drainage water being evacuated from a roof surface may be transferred from sump drain frame100to drain pipe122through outlet conduit102.

In various embodiments, with additional reference toFIG. 7C, an outlet conduit (e.g., outlet conduit758A-758C) may be a separate piece from and coupled to a sump drain frame (e.g., sump drain frame700B). An outlet conduit may comprise an interface to couple with a complementary interface of the sump drain frame. For example, an outlet conduit may comprise threading (e.g., threading762) or other specific geometry or configuration to couple with the sump drain frame. The sump drain frame may comprise a complementary threading and/or geometry or configuration (e.g., complementary threading764) to receive and couple with the outlet conduit. In various embodiments, an outlet conduit may comprise an outer wall configured to converge, and form at least a partial seal, with the sump drain frame (e.g., a drain bowl, inlet conduit, first land, or ramp, of the sump drain frame). In various embodiments, an outlet conduit may comprise a transitional surface, which may be angled from a surface configured to converge, and form at least a partial seal, with the sump drain frame (e.g., a drain bowl, inlet conduit, first land, or ramp, of the sump drain frame). The transitional surface (such as those depicted in outlet conduits758A-758C) may be configured to converge a flow of drainage water into the outlet conduit and/or drain pipe. Accordingly, such a transitional surface may be a drain bowl.

Referring back toFIGS. 1-3, in various embodiments, a drain inlet may comprise a drain bowl104and/or an inlet conduit106. In various embodiments, drain bowl104may be positioned above (in the positive Y-direction) and connected to outlet conduit102. Drain bowl104may comprise any suitable shape, such as a frusto-conical or frusto-pyramidal shape. In various embodiments, drain bowl104may be directly coupled to a first land (e.g., first land108) and/or a ramp (e.g., ramp110). In various embodiments, drain bowl104may be coupled to an inlet conduit106, which is coupled to and/or spanning between drain bowl104and first land108and/or ramp110. Drain bowl104may be configured to converge a flow of drainage water from ramp110, first land108, and/or inlet conduit106(in the negative Y-direction) into an outlet conduit and/or drain pipe.

Inlet conduit106may comprise any suitable shape, such as an annular shape comprising an annular inner surface124and an annular outer surface126. A diameter, D1, of annular outer surface126of inlet conduit106may be between approximately 8 inches (20.32 cm) and 16 inches (40.64 cm), be between approximately 10 inches (25.40 cm) and 14 inches (35.56 cm), or approximately 12 inches (30.48 cm), in various embodiments. Annular inner surface124may be configured to receive and couple to drain bowl strainer200.

For example, in various embodiments, inlet conduit106and drain bowl strainer200may comprise threads, apertures to receive one or more fasteners, or a geometrical interface configured couple drain bowl strainer200to inlet conduit106. In various embodiments, and with specific reference toFIG. 1, inlet conduit106may comprise one or more protrusions128and one or more recesses130. Protrusions128of inlet conduit106may be configured to align with recesses204on drain bowl strainer200and recesses130of inlet conduit106may be configured to align with protrusions202on drain bowl strainer200. In such a way, drain bowl strainer200may be easily coupled to and/or removed from sump drain frame100by placing drain bowl strainer200in inlet conduit106and may be restrained from rotating about the Y-axis relative to sump drain frame100.

In various embodiments, an inlet conduit may be directly coupled to the outlet conduit. In such cases, a transitional surface may be disposed between the inlet conduit and the outlet conduit, and/or between a ramp or first land and the inlet conduit. The transitional surface may be configured to converge a flow of drainage water. Such a transitional surface may be referred to as a drain bowl.

In various embodiments, the drain inlet (e.g., comprising inlet conduit106and/or drain bowl104) may be coupled to first land108. Drain bowl104may be coupled to first land108by inlet conduit106coupled to and spanning between drain bowl104and first land108. In various embodiments, drain bowl104may be adjacent to and connected to first land108. First land108may be an annulus extending around (e.g., circumferentially around) the drain inlet, and may be configured to deliver drainage water thereto (e.g., to inlet conduit106and/or drain bowl104), and/or to outlet pipe102. For example, in various embodiments, an upper surface132of first land108may be flush with an inlet surface206of drain bowl strainer200such that water may flow from first land108to inlet conduit106without having to first travel up a gradient. As a result, standing water is unlikely to form on first land108. In various embodiments, with reference toFIGS. 7A and 7B, a drain bowl strainer750may be disposed on and/or coupled to a first land (e.g., first land708) of a sump drain frame (e.g., sump drain frame700A).

In various embodiments, first land108may comprise a width, W1, of between approximately 0 inches (0 cm) and 4 inches (10.16 cm), between approximately 1 inch (2.54 cm) and 3 inches (7.62 cm), or approximately 2 inches (5.08 cm). First land108may comprise a lower surface136configured to be placed on top of and couple to a deck210. In various embodiments, deck210may comprise any suitable material, for example, a wood (e.g., plywood), polymer, ceramic, metal, or composite material. Deck210may comprise a height, H1, between approximately 0 inches (0 cm) to 8 inches (20.32 cm), between approximately 2 inches (5.08 cm) and 6 inches (15.24 cm), or approximately 4 inches (10.16 cm), in various embodiments.

In various embodiments, first land108may be adjacent to and connected to ramp110. In various embodiments, ramp110may be coupled to the drain inlet (e.g., inlet conduit106and/or drain bowl104) by first land108coupled to and spanning therebetween. That is, first land108may be connected to and/or span between drain bowl104and/or inlet conduit106and ramp110. In various embodiments, ramp110may be coupled directly to the drain inlet (e.g., inlet conduit106and/or drain bowl104). Ramp110may be configured to be at least partially positioned on a top surface of the deck210(in the Y-direction) and contain a sump insulation underneath ramp110and above deck210. Ramp110may comprise any suitable shape, such as semi-spherical (e.g., a bowl shape), frusto-conical, frusto-pyramidal, or the like. The ramp may be configured to converge drain water into or onto first land108, the drain inlet (e.g., inlet conduit106and/or drain bowl104), and/or outlet conduit102. In various embodiments, ramp110may span between a ramp upper point and a lower point, wherein the ramp upper point may be higher (in the Y-direction) than the ramp lower point. The ramp lower point may be coupled to a first land, a drain inlet (e.g., an inlet conduit and/or a drain bowl), and/or an outlet conduit. In various embodiments, a ramp may comprise a protrusion extending outward from the ramp. Such a protrusion may extend for any suitable length around the sump drain frame about the drain inlet. For example, a protrusion may comprise a step or flat surface upon which another component of the sump drain system couples, such as a drain bowl strainer.

In various embodiments, ramp110may comprise one or more sections138comprising incline planes such that drainage water may flow from a roof surface to the drain inlet and onward to drain pipe122. In various embodiments, sections138may extend 360° around first land108. In various embodiments, ramp110may comprise four sections138, each forming one fourth of the entire ramp110; however, ramp110is not limited in this regard. Ramp110may comprise two, three, five, six, or any other suitable number of sections138.

In various embodiments, each section138of ramp110may comprise a width, W2, and a height, H2. In various embodiments, width W2may be between approximately 8 inches (20.32 cm) and 16 inches (40.64 cm), be between approximately 10 inches (25.40 cm) and 14 inches (35.56 cm), or approximately 12 inches (30.48 cm). Height H2may be between approximately 0 inches (0 cm) and 8 inches (20.32), between approximately 2 inches (5.08 cm) and 6 inches (15.24 cm), or approximately 4 inches (10.16 cm) in various embodiments. However, each section138of ramp110is not limited in this regard and may comprise any suitable width and height. Further, while illustrated with each section138comprising the same width and height, sections138of ramp110are not limited in this regard and may comprise varying dimensions.

In various embodiments, with reference toFIGS. 7A-7B and 8A-8B, a sump drain frame may comprise sump channels in the ramp portion of the sump frame. For example, sump drain frames700A and800may comprise sump channels703within ramps710and810, respectively. The sump channels may be channels recessed into the ramp of the sump drain frame. On the underside of a sump drain frame comprising sump channels, there may be protrusions reflecting the recesses of the sump channels. Sump channels may be disposed in any suitable location(s) in the ramp of a sump drain frame. For example, sump channels may be disposed between ramp sections of a sump drain ramp, such as sump channels703being disposed between ramp sections738of sump drain frames700A and800. During manufacturing of a sump drain frame (e.g., injection molding and/or vacuum forming process), webbing may create wrinkles in various components of the sump drain frame, such as in the ramp. Such wrinkles may be utilized and formed to create the sump channels. The sump channels may span any suitable length along the ramp of a sump drain frame. For example, the sump channels may span from a point on the ramp (e.g., from a top of the ramp) to the inlet conduit, drain bowl, and/or outlet conduit, such that at least one sump channel is in fluid communication with the inlet conduit, drain bowl, and/or outlet conduit. Accordingly, sump channels may be configured to further direct water toward the inlet conduit706(similar to inlet conduit106discussed herein), drain bowl704(similar to drain bowl104discussed herein), and/or outlet conduit702(similar to outlet conduit102discussed herein) of sump drain frames700A and/or800. Sump channels may also provide greater structural strength of the ramp and sump drain frame.

In various embodiments, ramp110may be adjacent to and connected to second land112. Ramp110may be connected and/or span between the drain inlet and/or first land108and second land112. Second land112may comprise a substantially flat surface surrounding each side of ramp110(wherein “substantially” means within 10% of flat). Second land112may be configured to receive a roof membrane212which may be coupled to second land112. For example, roof membrane212may be positioned on an upper surface140of second land112and thermally coupled to, chemically coupled to, coupled by way of adhesive, cured to, welded to or otherwise coupled to upper surface140of second land112. In various embodiments, second land112may comprise a width, W3, between approximately 0 inches (0 cm) and 8 inches (20.32 cm), between approximately 2 inches (5.08 cm) and 6 inches (15.24 cm), or approximately 4 inches (10.16 cm). However, second land112is not limited in this regard and may comprise any suitable length.

In various embodiments, second land112may be adjacent to and connected to insulation receiving surface114. In various embodiments, ramp110may be coupled to insulation receiving surface114by second land112coupled to and spanning therebetween. That is, second land112may be coupled to and span between ramp110and insulation receiving surface114. Insulation receiving surface114may be substantially perpendicular to second land112and extend downward (in the negative Y-direction) from second land112(wherein “substantially” means within 10% of perpendicular). In various embodiments, insulation receiving surface114may be coupled directly to ramp110, such as at an upper point of ramp110, and extend downward therefrom. In various embodiments, insulation receiving surface114may comprise an outer surface142and an inner surface144. Outer surface142may be adjacent to and abut roof insulation216. Outer surface142may be configured to couple to an insulation retention clip214. In various embodiments, roof insulation216may comprise a polyisocyanurate material, expanded polystyrene materials, extruded polystyrene material, or a lightweight insulating concrete material. In various embodiments, with additional reference toFIG. 7A, an insulation receiving surface (e.g., insulation receiving surface714) may comprise ribs715. Ribs may be recessed or protruding from insulating receiving surface714. Ribs715may be configured to strengthen the insulation receiving surface and/or the sump drain frame.

Together, inner surface144of second land112, ramp110, insulation receiving surface114, and/or deck210may be configured to contain or at least partially enclose sump insulation146, which may be a polyisocyanurate material, expanded polystyrene material, extruded polystyrene material, pourable or sprayable polyurethane material, or mineral wool material in various embodiments. Specifically, after sump drain frame100is formed, sump insulation146may be sprayed or otherwise coupled to an underside of ramp110and second land112such that sump drain frame100may be installed in sump drain system1000already containing sump insulation146coupled to sump drain frame100. In various embodiments, the portion of sump drain frame100configured to receive the sump insulation may be covered and/or enclosed by a cover790coupled to a lower surface of sump drain frame100. The cover may span along any suitable area on the lower surface of the sump drain frame, such as across the entire sump drain frame lower surface, or just over the portion of the sump drain frame configured to receive the sump insulation. Such a cover may comprise any suitable material, such as a polymeric material, glass-reinforced recycled paper, fiberglass mat, and/or the like. The cover may function to provide better coupling between the sump drain frame and the roof deck (providing more surface area for adhesion and/or other coupling between the two), and/or may provide protection to the sump insulation within the sump drain frame. In various embodiments, insulation receiving surface114may comprise a height approximately equal to a height of roof insulation216and/or ramp110. As such, in various embodiments, a height of insulation receiving surface114may be between approximately 0 inches (0 cm) and 8 inches (20.32), between approximately 2 inches (5.08 cm) and 6 inches (15.24 cm), or approximately 4 inches (10.16 cm).

In various embodiments, insulation receiving surface114may comprise one or more apertures148configured to receive one or more fasteners218. Insulation retention clip214may comprise one or more apertures220configured to mate with the one or more apertures148in insulation receiving surface114and receive one or more fasteners218. In such a way, insulation retention clip214may be coupled to outer surface142of insulation receiving surface114and be configured such that a lower surface of insulation retention clip214abuts an upper surface of roof insulation216. As such, roof insulation216may be securely positioned proximate to outer surface142of insulation receiving surface114. An upper surface of insulation retention clip214may be flush with upper surface140of second land112such that roof membrane212may be positioned flatly across the upper surface of insulation retention clip214and upper surface140of second land112. In various embodiments, insulation retention clip214may comprise a width, W4and a height, H3. In various embodiments, width W4and/or height H3may be between approximately 0 inches (0 cm) and 4 inches (10.16 cm), between approximately 1 inch (2.54 cm) and 3 inches (7.62 cm), or approximately 2 inches (5.08 cm).

A sump drain frame or system may comprise an attachment portion by which the sump drain frame or system couples to a roof deck and/or roof insulation. In various embodiments, the attachment portion may comprise an attachment flange (e.g., attachment flange116. In such embodiments, insulation receiving surface114may be adjacent to and connected to attachment flange116, in accordance with various embodiments. In various embodiments, an attachment flange may be coupled to the ramp and/or second land. For example, an attachment flange may be coupled to the ramp and/or second land by the insulation receiving surface being coupled to and spanning between. An attachment flange may extend outward or inward from insulating receiving surface114. Attachment flange116may comprise one or more apertures150configured to receive one or more fasteners218and couple sump drain frame100to deck210. However, attachment flange216is not limited in this regard and may be coupled to deck210by way of adhesive or using any other suitable technique. Attachment flange116may comprise an upper surface152and lower surface154. Upper surface152may be configured to abut to a lower surface of roof insulation216, while lower surface154may be configured to abut deck210.

In various embodiments, a sump drain frame may comprise an attachment portion that is comprised in a portion of the sump drain frame within the perimeter of the sump drain frame defined by the insulation receiving surface. For example, with reference toFIGS. 7A-7C, sump drain frames700A and700B of sump drain systems7000A and7000B, respectively, may comprise an attachment portion disposed within the perimeter defined by insulation receiving surface714, e.g., in second land712(similar to second land112). Attachment portion may comprise a fastener aperture701through which a fastener718(e.g., a screw, nail, anchor, and/or the like) may be disposed to couple sump drain frames700A and700B to insulation232and/or roof deck210. A fastener aperture may be disposed in any suitable portion of a sump drain frame, such as through a second land (e.g., through second land712, as shown inFIGS. 7A-7C), through a ramp (e.g., ramp710), a first land (e.g., first land708), an inlet conduit (e.g., inlet conduit706), and/or a drain bowl704. A fastener may be disposed through any such fastener aperture to couple the sump drain frame to the roof insulation and/or roof deck. In various embodiments, a fastener aperture may be configured such that the fastener, when installed to couple the sump roof frame to the roof deck, rests below the surface in which the fastener aperture is disposed. Accordingly, in embodiments in which a fastener aperture is disposed in second land (e.g., second land712), roof membrane may be disposed over the fastener aperture and the fastener disposed therein. In various embodiments, a fastener may be disposed through any component of a sump drain system to couple the sump drain system to a roof deck.

In various embodiments, as another example of an attachment portion that is comprised in a portion of the sump drain frame within the perimeter of the sump drain frame defined by the insulation receiving surface, a sump drain may comprise an attachment portion comprising an attachment flange. Such an attachment flange may comprise a recessed attachment flange. For example, with reference toFIGS. 8A-8B, sump drain frame800of sump drain system8000may comprise an attachment portion comprising recessed attachment flanges816. Recessed attachment flanges816may be disposed within the perimeter defined by insulation receiving surface814. Insulation receiving surface814may comprise recesses815disposed therein. Recesses in the insulation receiving surface may span inwardly (i.e., toward the drain inlet) from the insulation receiving surface for any suitable distance. Recesses in the insulation receiving surface may span in the Y-direction for any suitable distance, including spanning through the surface coupled to the insulation receiving surface and/or above the recess (e.g., the ramp and/or the second land). Recesses815may comprise a respective recessed attachment flange816disposed therein. For example, a recessed attachment flange816may be the lower boundary of a recess815. One or more recessed attachment flange816may comprise a fastener aperture801disposed therethrough, through which a fastener818may be disposed to couple sump drain frame800to insulation232and/or roof deck210. A sump drain frame may comprise any suitable number of recesses in the insulation receiving surface (e.g., four recesses815in each side of the insulation receiving surface814). Roof membrane (e.g., roof membrane212) may be disposed over recesses in the insulation receiving surface.

Attachment portions of sump drain frames comprised within the perimeter defined by the insulation receiving surface of a sump drain frame may allow the sump drain frame to easily be disposed and fit within a desired shape or within desired dimensions. For example, if replacing a drain or sump system in an existing roof (i.e., retrofitting a sump drain frame or system in an existing roof), having all components of a sump drain frame within a certain dimension may facilitate easy placement of the sump drain frame within the hole in the roof insulation. Accordingly, the insulation receiving surface (e.g., insulation receiving surfaces714and814) may easily be disposed to abut insulation716, which may be preexisting in its position.

In various embodiments, sump drain frame100may comprise a square shape when viewed in the X-Z plane. For example, sump drain system1000may be sized and shaped such that sump drain frame100may be installed or retrofitted on existing roofing systems without the need to trim or otherwise alter other components of the roofing system for installation. For example, in various embodiments, sump drain frame100may comprise an overall width, OW, from an edge of second land112on one side of sump drain frame100to an edge of second land112on an opposite side of sump drain frame100. In various embodiments, overall width OW may be between approximately 24 inches (60.96 cm) and 72 inches (182.88 cm), between approximately 36 inches (91.44 cm) and approximately 60 inches (152.4 cm), or approximately 48 inches (121.92 cm). As such, because roof insulation components (such as roof insulation paneling) are often manufactured such that at least one side of the insulation component measures 48 inches, sump drain frame100comprising an overall width OW of approximately 48 inches may fit existing roofing systems without the need for alteration of various components.

In accordance with various embodiments, sump drain frame100may be manufactured as a single, continuous, watertight component. Because of this, sump drain frame100may prevent leaks from forming along a flow path of drainage water better than existing sump drain systems comprising multiple components coupled together by compression fasteners or other components. In addition, sump drain frame100may be configured such that a connection point between roof membrane212and sump drain frame100is moved outward and away from drain pipe122. As such, roof membrane212may be positioned outside of areas likely to accumulate large amounts of standing water (such as near an interface with drain bowl strainer200), thereby making sump drain frame100and sump drain system1000less likely to experience leaks. Further, because sump drain frame100comprises a single, continuous, watertight component, sump drain frame100may be configured to house sump insulation146directly underneath ramp110. As such, sump drain frame100may be easier to manufacture and install, while still complying with applicable construction codes requiring insulation proximate to the drain.

With reference now toFIGS. 4A-4H, sump drain frame100of sump drain system1000may comprise various materials having various structures.FIG. 4Aillustrates a sump drain system1000comprising a sump drain frame100comprising a TPO or PVC material, in accordance with various embodiments. Roof membrane212may also comprise a TPO or PVC material. In various embodiments, roof membrane212and second land112of sump drain frame100may be thermally welded together such that a watertight seal is formed between roof membrane212and sump drain frame100. However, as previously stated, roof membrane212may be coupled to second land112utilizing any suitable method.

FIG. 4Billustrates another embodiment of sump drain system1000. In some instances, due to various construction codes, it may be necessary to extend sump insulation146beneath other portions of sump drain frame100. Accordingly, in various embodiments, sump drain insulation146may extend along a lower surface of ramp110, lower surface136of first land108, along annular outer surface126of inlet conduit106, along an outer surface of drain bowl104and terminate at annular outer surface120of outlet conduit102. As such, in various embodiments, sump drain frame100may incorporate sump insulation146along other portions of sump drain frame100in addition to below ramp110and/or second land112.

Referring now toFIG. 4C, sump drain system1000may comprise one or more heat traces222, in accordance with various embodiments. Heat traces222may comprise a first heat trace224connected to one side of outlet conduit102and a second heat trace226connected to an opposite side of outlet conduit102. First heat trace224and second heat trace226may be configured to contact outlet conduit102, drain bowl104, inlet conduit106, first land108, ramp110, and/or second land112in various embodiments, however, first heat trace224and second heat trace226are not limited in this regard and may be configured to contact any number of the aforementioned components.

First heat trace224and second heat trace226may contact any of the aforementioned components at any location. For example, in various embodiments, first heat trace224and second heat trace226may be configured to wrap around annular components such as outlet conduit102, drain bowl104, or inlet conduit106, or be configured to spread outward along multiple paths along a lower surface of ramp110, for example. First heat trace224and second heat trace226may be configured to conduct an electric current and heat the various components contacted by first heat trace224and/or second heat trace226. Accordingly, in various embodiments, first heat trace224and second heat trace226may be configured to heat various surfaces of sump drain frame100such that ice formation on these components is prevented and/or removed in freezing conditions.

Moving on and with reference toFIG. 4D, in various embodiments, sump drain frame100may comprise an EPDM material. In various embodiments, the EPDM material of the sump drain frame100and the roof membrane212may be vulcanized, and may be unable to be coupled to second land112of sump drain frame100by thermal welding. As such, in various embodiments, second land112may be configured to receive an adhesive228such as a double-sided seam tape, for example. Adhesive228may be placed on upper surface140of second land112and be configured to receive a bottom surface of roof membrane212. As such, roof membrane212be coupled to sump drain frame100comprising materials other than PVC or TPO utilizing various methods.

With reference toFIG. 4E, in various embodiments, an interface between a composite modified asphalt roof membrane212and second land112of sump drain frame100may be sealed using a polymethyl methacrylate material (or PMMA) or other suitable material. For example, roof membrane212may be coupled to second land112of sump drain frame100utilizing one or more of the methods previously disclosed. A PMMA material such an acrylic or an acrylic glass material may be placed over roof membrane212, second land112, ramp110, and/or other portions of sump drain frame100. PMMA may provide additional waterproofing and UV resistance such that the interface between roof membrane212and sump drain frame100.

In various embodiments, it may be desirable to position sump drain frame100higher (in the positive Y-direction) relative to deck210. Accordingly, in various embodiments, sump drain frame100may be coupled to one or more blocks230positioned between attachment flange116of sump drain frame100and deck210. Each block230may comprise a wood material or a material similar to that of deck210and comprise a thickness of between approximately 0 inches (0 cm) and 4 inches (10.16 cm), between approximately 1 inch (2.54 cm) and 3 inches (7.62 cm), or approximately 2 inches (5.08 cm). As such, sump drain frame100may be offset a distance from deck210(in the positive Y-direction). In various embodiments, additional insulation in the form of board stock insulation232may be positioned in the gap between sump drain frame100and deck210as well as the other areas on top of deck210. Board stock insulation232may at least partially extend below sump insulation146, for example. In such a way, blocks230may allow for additional insulation to be utilized in conjunction with sump drain system1000.

Referring now toFIG. 4G-FIG. 4I, sump drain system1000may be configured to couple to an overflow system2000, in accordance with various embodiments. For example, referring toFIG. 4G, overflow system2000may be configured to allow drainage water to be evacuated from the roof in the event other drains, such as the sump drain, become clogged due to the presence of debris or ice. Overflow system2000may be configured to be installed along with the sump drain system such as at a location adjacent to the sump drain system, in accordance with various embodiments. Overflow system2000may comprise an overflow frame300substantially similar to sump drain frame100in various embodiments. For example, overflow frame300may comprise an outlet conduit302, drain bowl304, inlet conduit306, insulation receiving surface310, and attachment flange312similar to those described with respect to sump drain frame100. However, in various embodiments, overflow frame300may comprise a land308comprising a substantially flat surface extending from inlet conduit306to insulation receiving surface310. In such a way, land308of overflow frame300may replace first land108, ramp110, and second land112of sump drain frame100(with momentary reference toFIG. 2).

Overflow system2000may comprise a drain bowl strainer400similar to those described with respect to sump drain system1000, however, drain bowl strainer400may be inserted into inlet conduit306such that a distance, d, exists between a bottom of drain bowl strainer400and land308when drain bowl strainer400is installed in overflow frame300. As such, drainage water may not begin flowing into drain bowl strainer400until standing water reaches a predetermined elevation (greater than d) in the areas of the roof surrounding overflow system2000. As previously stated, standing water may result in structural failure of the underlying roof system due to the weight of the standing water and overflow system2000may provide an additional outlet for such standing water.

Referring now specifically toFIG. 4H, a cross-sectional view of a dual emergency sump drain system3000is illustrated, in accordance with various embodiments. Dual emergency sump drain system3000may comprise a frame500comprising a sump drain frame, similar to sump drain frame100described with reference toFIG. 1-FIG. 3, coupled to an overflow frame. Sump drain frame and overflow frame may be formed together as a single, continuous component to form frame500utilizing any of the suitable manufacturing techniques previously mentioned, however, are not limited in this regard and may comprise separate components coupled together after each component is manufactured.

Moving from left to right, frame500may comprise a first attachment flange502connected to a first insulation receiving surface504. First insulation receiving surface504may be connected to a first land506which be connected to a first ramp508. First ramp508may comprise a decline plane extending downward (in the negative Y-direction) and connecting to a second land510. Second land510may be connected to a sump inlet conduit512which may connect to a sump drain bowl514connected to sump outlet conduit516. In various embodiments, second land510may also be connected to a second ramp518which may comprise an incline plane extending upward (in the positive Y-direction).

In various embodiments, second ramp518may connect to a third land520. Third land520may be connected to an overflow inlet conduit522, which may connect to an overflow drain bowl524. Overflow drain bowl524may connect to an overflow outlet conduit526. In various embodiments, third land520may also be connected to a third ramp528. Third ramp528may comprise an incline plane extending upward (in the positive Y-direction) from third land520to a fourth land530. Fourth land530may be connected to a second insulation receiving surface532which may connect to a second retention flange534.

In various embodiments, first ramp508may comprise a first height, H1, second ramp518may comprise a second height, H2, and third ramp528may comprise a third height, H3. In various embodiments, first height H1may be approximately equal to third height H3. First height H1and third height H3may each be greater than second height H2in various embodiments. As such, drainage water may be configured to flow down first ramp508and/or third ramp528toward sump inlet conduit512. In the event sump inlet conduit512, sump drain bowl514, and/or sump outlet conduit516become clogged, standing water may form on second land510, first ramp508, and/or second ramp518. Because a second height H2of second ramp518is less than a first height of first ramp508and a third height of third ramp528, drainage water may flow into overflow inlet conduit522before spilling out onto the remaining portions of the roof proximate to first land506and/or fourth land530.

Referring now toFIG. 4I, in various embodiments, dual emergency sump drain system3000may comprise a flat surface536extending between the sump drain and the overflow drain instead of/in addition to a second ramp. For example, in various embodiments, first height H1of first ramp508may be approximately equal to third height H3of third ramp528. Rather than comprising a second ramp comprising a second height less than H1and/or H2, a drain bowl strainer538of the overflow drain may be offset a distance, d (in the positive Y-direction) from flat surface536. In various embodiments, d may be less than H1and/or H3. As such, similar to the dual emergency sump drain system3000ofFIG. 3G, drainage water may flow into the overflow drain before spilling out onto the remaining portions of the roof proximate to first land506and/or fourth land530.

A method of constructing sump drain system1000is illustrated inFIGS. 5A-5G. Referring initially toFIG. 5A, deck210may be constructed of various materials and be configured to support other components of sump drain system1000. A hole may be cut in deck210and be configured to receive an inlet conduit106, drain bowl104, and outlet conduit102of a sump drain frame100(FIG. 5A). Sump drain frame100(already comprising insulation retention clip214) may be aligned with the hole in deck210and be fastened to the deck using a plurality of fasteners218extending through the plurality of apertures150in attachment flange116(FIG. 5B). Roof insulation216may be positioned around sump drain frame100(FIG. 5C). Roof insulation216may align with at least one side of sump drain frame100and may comprise a staggered pattern of multiple boards, in various embodiments. Roof insulation216may be positioned between insulation retention clip214and attachment flange116and contact insulation receiving surface114(FIG. 5D). Roof membrane212may be placed over roof insulation216and coupled to second land112(FIG. 5E). Drain bowl strainer200may be coupled to inlet conduit106of sump drain frame100(FIGS. 5F and 5G).

Referring now toFIGS. 6A-6E, a sump drain frame600may be configured such that sump drain frame600may be inserted into existing roofing systems, in accordance in various embodiments. Stated otherwise, existing roofing systems may be retrofitted with sump drain system1000or sump drain frame600such that the existing roofing system may exhibit the same favorable anti-leaking qualities associated with sump drain system1000and/or sump drain frame600. As such, sump drain system1000and/or sump drain frame100may be included as part of a newly assembly roofing drainage system or included in older, existing roofing drainage systems.

In various embodiments, sump drain frame600may be substantially similar to sump drain frame100described with reference toFIG. 2, however, sump drain frame600may comprise a structure suitable for fitting within existing roofing systems. For example, in various embodiments, in contrast to drain bowl104and inlet conduit106(with momentary reference toFIG. 2), sump drain frame600may comprise a curved annular portion656and a linear annular portion658. Curved annular portion656may be configured to guide water to linear annular portion658, which may be configured to direct water to drain pipe122.

Sump drain system1000may comprise a drain bowl strainer200which may be similar to the drain bowl strainer described with reference toFIG. 2. However, because sump drain frame600may be configured to fit within existing roofing systems without the need to drastically alter the structure of the roofing system, drain bowl strainer200may be configured to couple directly sump drain frame (for example, a land of sump drain frame) without the need to geometrically align with the structure of sump drain frame600. For example, in various embodiments, drain bowl strainer200may be coupled directly to sump drain frame600using one or more fasteners234. In various embodiments, fasteners234may comprise any suitable structure for removably or permanently fixing drain bowl strainer200to sump drain frame600, including screws, nails, bolts, brazed joints, welded joints, or any other suitable connection method. In various embodiments, fasteners234may be coupled to strainer200and disposed into recesses734(as depicted inFIGS. 7B and 8B) to couple strainer200to the sump drain frame. In various embodiments, fasteners may be coupled to the sump drain frame and disposed into the strainer to couple the strainer to the sump drain frame (e.g., as shown inFIG. 7C). The strainer may be coupled to any suitable component of a sump drain frame, such as a drain bowl, inlet conduit, first land, ramp, and/or second land.

In various embodiments, and similar to the sump drain frame described with reference toFIG. 4F, additional insulation may be required in certain roofing applications. As such, sump drain frame600may be coupled directly to board stock insulation232. In various embodiments, sump drain frame600may be removably or permanently coupled to deck210by fastener218. For example, in various embodiments, a screw, nail, bolt, or the like may be inserted through a portion of sump drain frame600, through board stock insulation232, and into deck210. In various embodiments, sump drain system1000may include blocks (similar to blocks230described with reference toFIG. 4F) to assist in coupling sump drain frame600to deck210, however, is not limited in this regard and may not comprise blocks in certain embodiments.

Sump drain frame600may further comprise a membrane terminal feature660extending around a perimeter of sump drain frame600. For example, in certain applications, it may be beneficial to quickly cut away a portion of the surrounding roof membrane212to install sump drain frame600. In such applications, sump drain frame600may be first coupled to deck210and later be covered with roof membrane212. Membrane terminal feature660may provide a tracing path for the individual installing sump drain frame600. For example, after covering sump drain frame with roof membrane212, the individual may insert a knife edge or other tool to trace the profile defined by the membrane terminal feature and quickly and efficiently remove the excess portions of roof membrane212. In various embodiments, membrane terminal feature660may comprise a concave or convex feature of any desired cross-sectional shape. In this regard, membrane terminal feature660may decrease the time and effort required to install sump drain frame600into existing roofing systems.

Referring now toFIG. 6BandFIG. 6C, sump drain frame600may further comprise a reinforcing feature configured to increase stability to linear annular portion658. For example, in various embodiments, sump drain frame600may include an outer reinforcing feature236(FIG. 6B) and/or an inner reinforcing feature238(FIG. 6C). Outer reinforcing feature236may be coupled to an outer surface of linear annular portion658, while inner reinforcing feature may be coupled to an inner surface of linear annular portion658. Outer reinforcing feature and/or inner reinforcing feature may comprise any suitable material configured to increase the stability of linear annular portion, for example, a metal alloy material or polymer material.

Referring now toFIG. 6DandFIG. 6E, in some instances, drain pipe122be comprise a diameter which does not correspond to a diameter of linear annular portion658, thereby making a no-hub connector or other attachment option undesirable or unachievable. As such, in various embodiments, sump drain system1000may comprise a suitable structure or device capable of coupling linear annular portion658of sump drain frame600to drain pipe122despite the mismatch in diameters.

Specifically, with reference toFIG. 6D, sump drain frame600may be equipped with a mechanical seal240coupled to linear annular portion658. Mechanical seal240may comprise any suitable structure configured to mate with an inner surface of linear annular portion658and expand to contact an inner surface of pipe drain122. In this regard, linear annular portion658comprising a diameter less than pipe drain122may be inserted into pipe drain122yet still constrain movement of linear annular portion658and sump drain frame600relative to drain pipe122. In various embodiments, mechanical seal240may comprise a screw element coupled to a head element, wherein the screw element may be configured to increase a diameter of the head element in response to being rotated in a first direction, while being configured to decrease a diameter of the head element in response to being rotated in a second direction opposite the first direction. This functionality may allow linear annular portion658to be inserted into drain pipe122and mechanical seal240may exert a radial force on the inner surface drain pipe122, thereby constraining movement of linear annular portion658relative to drain pipe122. In the event sump drain frame600requires removal, the screw element may be rotated in the second direction, thereby decreasing the diameter of the head element and removing the radial force on the inner surface of drain pipe122. While discussed herein as comprising a screw element and a head element, mechanical seal240is not limited in this regard and may comprise of a ratcheting mechanism or a worm gear mechanism may exert a radial force on the inner surface drain pipe122. Further, while discussed herein as exerting a radial force on an inner surface of drain pipe122, sump drain system is not limited in this regard. For example, in various embodiments, linear annular portion658may comprise a diameter greater than that of drain pipe122. In such embodiments, mechanical seal240may be configured to apply a radial force to an outer surface of drain pipe122and be equipped with a component to prevent water from leaking between linear annular portion658and drain pipe122as water exits from linear annular portion658. Numerous embodiments are contemplated herein.

Referring now toFIG. 6E, sump drain frame600may be equipped with a swelling seal242coupled to linear annular portion658. Swelling seal242may comprise any suitable material configured to mate with an inner surface of linear annular portion658and expand to contact an inner surface of pipe drain122. In this regard, linear annular portion658comprising a diameter less than pipe drain122may be inserted into pipe drain122yet still constrain movement of linear annular portion658and sump drain frame600relative to drain pipe122. In various embodiments, swelling seal242may comprise an expanding foam material, for example, a polyurethane foam, silicone seal, or a water reactive composite butyl compound enhanced with sodium bentonite clay or polymers such as sodium polycarbonate. This functionality may allow linear annular portion658to be inserted into drain pipe122and swelling seal242may exert a radial force on the inner surface drain pipe122, thereby constraining movement of linear annular portion658relative to drain pipe122. While discussed herein as exerting a radial force on an inner surface of drain pipe122, sump drain system is not limited in this regard. For example, in various embodiments, linear annular portion658may comprise a diameter greater than that of drain pipe122. In such embodiments, swelling seal242may be configured to apply a radial force to an outer surface of drain pipe122and be equipped with a component to prevent water from leaking between linear annular portion658and drain pipe122as water exits from linear annular portion658. Numerous embodiments are contemplated herein.