Linear drain system

A linear drain system may include a main body including a first end, a second end longitudinally opposed to the first end, and a top surface, a drain opening formed through the main body, and a drain channel formed in the top surface and extending longitudinally from proximate the first end to proximate the second end and in fluid communication with the drain opening, wherein the drain channel includes a V-shape in cross-section.

FIELD

The present disclosure is generally related to drain systems and, more particularly, to a modular, low profile linear drain system for floors.

BACKGROUND

Water drains are used in various applications. One such application is a trench drain. One type of trench drain is a linear floor drain, for example, used in shower floors. Linear floor drains typically include a U-shaped channel depending downwardly from and located under a floor surface. The channel includes generally horizontal sidewalls depending upwardly from and surrounding a drain trough. The drain trough is configured to convey liquid (e.g., water) entering the channel to a drainpipe.

Typically, a trench drain includes a channel depth equal to or greater than a channel width (e.g., the lateral distance between the sidewalls). Disadvantageously, due to the channel depth of traditional trench drains, installation of a linear floor drain may be limited. For example, the floor must be deep enough to accommodate the channel depth; otherwise, a linear floor drain may not be an available drain option.

One solution to this disadvantage is to lower the subfloor below the drain floor surface in order to increase the available depth needed for the linear floor drain. Disadvantageously, this solution requires substantial modification to the floor, for example, requiring cutting out and splicing portions of the underlying floor joists.

Another solution to this disadvantage is to raise the drain floor surface above the surrounding floor surface in order to increase the available depth needed for the linear floor drain. Disadvantageously, this solution creates a physical step up to the drain floor surface. Such a step up can create a barrier making it difficult, particularly for a disabled person, to access the drain floor surface. For example, the barrier can block entry to and exit from a shower.

Accordingly, those skilled in the art continue with research and development efforts in the field of floor drain systems.

SUMMARY

In one embodiment, the disclosed linear drain system may include a main body including a first end, a second end longitudinally opposed to the first end, and a top surface, a drain opening formed through the main body, and a drain channel formed in the top surface and extending longitudinally from proximate the first end to proximate the second end and in fluid communication with the drain opening, wherein the drain channel includes a V-shape in cross-section.

In another embodiment, the disclosed floor may include a subfloor, a drain extending at least partially through the subfloor, a drain system including a main body coupled to the subfloor, wherein the main body includes a first end, a second end longitudinally opposed to the first end, and a top surface, a drain opening formed through the main body, wherein the drain is coupled to the main body within the drain opening, and a drain channel formed in the top surface and extending longitudinally from proximate the first end to proximate the second end and in fluid communication with the drain opening, wherein the drain channel includes a V-shape in cross-section, an underlayment disposed over the subfloor and extending to the main body, and a floor covering disposed over the underlayment and extending to the drain channel.

In yet another embodiment, disclosed is a method for manufacturing a main body of a linear drain system, the method may include the steps of (1) forming a hub, wherein the hub includes a V-shaped hub drain channel and a drain opening at least partially intersecting the hub drain channel, (2) forming a pair of end caps configured to connect to the hub, wherein each end cap includes a V-shaped end cap drain channel, and (3) forming an extension configured to connect between the hub and one of the pair of end caps, wherein the extension includes a V-shaped extension drain channel.

In one embodiment, forming the hub may include molding a base material to form the hub drain channel and the drain opening. In another embodiment, forming the hub may include extruding a base material to form the hub drain channel and machining the drain opening through the hub.

Other embodiments of the disclosed systems and methods will become apparent from the following detailed description, the accompanying drawings and the appended claims.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings, which illustrate specific embodiments of the disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same element or component in the different drawings.

Referring toFIG. 1, disclosed is one embodiment of floor, generally designated100. Floor100may be any floor construction having a surface (e.g., drain floor surface112) where a liquid (e.g., water) may collect to be drained. As non-limiting examples, floor100may include, but is not limited to, a shower floor, a bathtub floor, pool deck floor (e.g., around a perimeter of a pool), a patio floor, a basement floor and the like.

As one non-limiting example, floor100(e.g., a shower floor, a bathtub floor, etc.) may include subfloor102. As one example, subfloor102may include, but is not limited to a three-quarter inch plywood subfloor. Drain104may at least partially extend through subfloor102, for example, through an opening cut or otherwise formed through subfloor102. As one non-limiting example, drain104may include a standard diameter drainpipe suitable to drain water from floor100(e.g., two-inch, etc.) As one general, non-limiting example, drain104may include a plastic drainpipe. As specific, non-limiting examples, drain104may include a drainpipe made from polyvinyl chloride (“PVC”), acrylonitrile butadiene styrene (“ABS”), cross-linked polyethylene (“PEX”) and the like. As another general, non-limiting example, drain104may include a metal drainpipe. As specific, non-limiting examples, drain104may include a drainpipe made from cast iron, copper, galvanized steel and the like.

Underlayment106may be laid over subfloor102. As examples, underlayment106may include, but is not limited to, concrete, mortar or screed. Underlayment106may include a slope (e.g., approximately a two-degree slope) directed toward drain104.

Waterproofing membrane108may be laid over underlayment106. As examples, waterproofing membrane108may include, but is not limited to, a waterproof fabric sheet (e.g., PVC or chlorinated polyethylene (“CPE”)) adhered to underlayment106(e.g., by glue or thinset cement) or a waterproof coating painted on underlayment106.

While the example ofFIG. 1illustrates a single waterproofing membrane108laid over underlayment106, those skilled in the art will recognize that additional waterproofing membranes (not explicitly illustrated) at additional and/or alternative locations may be used to construct floor100. As one example, waterproofing membrane108may be laid between subfloor102and underlayment106.

Those skilled in the art will further recognize that in certain floor constructions (e.g., shower or bath floors), waterproofing membrane108may extend (e.g., by approximately nine to twelve inches) up each side of the walls (not shown) surrounding floor100.

Floor100may also include floor covering114laid over waterproofing membrane108. Floor covering114may define drain floor surface112. The resulting drain floor surface112may include a slope matching the slope formed by underlayment106to direct water to drain104.

As one example, floor covering114may include tile110laid over waterproofing membrane108. Tile110may be adhered to waterproofing membrane108, for example, by tile cement, thinset cement, mortar, glue or the like. The resulting floor covering114(e.g., tile110) may include a slope matching the slope formed by underlayment106to direct water to drain104. As used herein, “tile” generally refers to any suitable floor covering including, but not limited to, ceramic, stone, marble, granite, porcelain, wood (e.g., teak) or the like.

While the example ofFIG. 1illustrates tile110as floor covering114of floor100, those skilled in the art will recognize that other suitable types of floor coverings114are also contemplated, such as, but not limited to, a manufactured solid shower pan or the like.

As another non-limiting example (not shown), floor100(e.g., a patio floor, a pool deck floor, a basement floor, etc.) may include successive layers of gravel and/or sand covered with bricks, concrete, tile or the like and including a drain (e.g., drain104).

Those skilled in the art will recognize that the structural features of floor100illustrated inFIG. 1are not necessarily proportioned to correct size.

Floor100may further include linear drain system, generally designated200. Drain system200is a trench drain assembly installed into floor100and coupled to drain104. Drain system200may collect drain water from drain floor surface112of floor100and direct the collected water to drain104for disposal. Drain system200may be installed into any suitable floor100. In one example of a shower application, drain system200may provide drainage for water falling and/or accumulating on the shower floor.

It is contemplated that the disclosed drain system200may also be installed in floors of rooms and areas other than showers, and also for drainage of liquids other than water so long as such liquids can flow along the declined drain floor surface112to drain system200.

Referring toFIG. 2, disclosed is one embodiment of drain system200. Drain system200may include main body252. Main body252may include first end208and a longitudinally opposed second end210. Main body252may include first side212and a laterally opposed second side214. Main body252may include top surface216and an opposed bottom surface218(not visible inFIG. 2). Main body252may include a longitudinal dimension, referred to herein as length L1, a lateral dimension, referred to herein as width W1, and a thickness dimension, referred to herein as thickness T1.

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of a lower-numbered item (e.g., a “first” item) and/or a higher-numbered item (e.g., a “third” item).

Main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206) (FIGS. 6, 8, 10 and 12) may include a relatively small thickness T1relative to the width W1. As one example, the thickness T1may be no more than approximately 20 percent of the width W1. As another example, the thickness T1may be no more than approximately 10 percent of the width W1. As another example, the thickness T1may be no more than approximately 5 percent of the width W1. As yet another example, the thickness T1of main body may be no greater than a combined thickness of subfloor102and underlayment106(FIG. 1).

The small thickness to width ratio of main body252may allow drain system200to be installed without modification to floor100(e.g., lowering subfloor102or raising drain floor surface112).

Referring toFIG. 2, and with reference toFIG. 1, drain system200may include drain opening222extending completely through main body252(e.g., from top surface216to bottom surface218). Drain opening222may be centrally positioned (e.g., laterally) between first side212and second side214(e.g., a central longitudinal axis A of drain system200may bisect drain opening222). Drain opening222may be positioned directly over and fluidly coupled to drain104(FIG. 1). The location of drain opening222may be dictated, for example, by the particular application, the location of drain104, the overall length L1of drain system200and the like.

While the examples ofFIG. 1andFIG. 2illustrates drain system200having a single drain opening222configured to be installed within floor100having a single drain104, drain system200may include more than one drain opening222formed through main body252to accommodate floor100having more than one drain104.

Drain system200may include a linear drain channel220formed in top surface216of main body252. Drain channel220may extend longitudinally from proximate (e.g., at or near) first end208to proximate second end210. Thus, drain channel220may run substantially the entire length L1of drain system200. Drain channel220may intersect and be in fluid communication with drain opening222.

Drain channel220may be longitudinally sloped (e.g., angled/pitched) downwardly from first end208and second end210, respectively, to drain opening222. The longitudinal slope of drain channel220may cause water, for example, entering drain channel220from drain floor surface112(FIG. 1), to flow, under the force of gravity, to drain opening222.

Drain channel220may serve as a drainage trough (e.g., a fluid flow path) to collect water from drain floor surface112(FIG. 1) and direct the collected water to drain opening222and ultimately to drain104. Accordingly, drain opening222may serve as an outlet for drain channel220. Upon draining through drain opening222, the water flows through drain104and into a plumbing network of the environment into which drain system200is installed (e.g., such as house plumbing, of which drain104is a part).

Top surface216may include first horizontal surface226extending laterally from first side212toward the longitudinal axis A and second horizontal surface228extending laterally from second side214toward the longitudinal axis A. Top surface216may further include first sloped (e.g., angled/pitched) surface230depending downwardly and extending laterally from first horizontal surface226and second sloped surface232depending downwardly and extending laterally from second horizontal surface228and intersecting first sloped surface230. First sloped surface230and second sloped surface232may form drain channel220. Drain channel220may be open facing upwards. Drain channel220may include a V-shape in cross-section, as best illustrated inFIGS. 1, 6, 8, 10, 12 and 14.

First horizontal surface226and second horizontal surface228may allow the construction of floor100(e.g., waterproof membrane108and/or floor covering114) to extend up to drain channel220, as illustrated inFIG. 1. First horizontal surface226and second horizontal surface228may each be substantially flat. First horizontal surface226and second horizontal surface228may be co-planar. First sloped surface230and second sloped surface232may each be substantially flat, as best illustrated inFIGS. 1, 6, 8, 10, 12and14. Alternatively, first sloped surface230and second sloped surface232may each include a slight curve in the lateral direction (not explicitly illustrated).

The interior of drain channel220may be formed such that the corners where first sloped surface230meets first horizontal surface226and where second sloped surface232meets second horizontal surface228form relatively sharp angle corners, as best illustrated inFIGS. 1, 6, 8, 10, 12 and 14. Alternatively, the interior of drain channel220may be formed such that the corners where first sloped surface230meets first horizontal surface226and where second sloped surface232meets second horizontal surface228form curved corners (not explicitly illustrated).

Referring toFIGS. 2 and 3, in one example embodiment, main body252may include a plurality of interconnected components to define length L1(FIG. 2). As one example, drain system200may include drain hub202, also referred to herein as hub202, one or more linear extensions204, also referred to herein as extensions204, and at least two end caps206. The total number of components forming main body252of drain system200(e.g., hubs202, extensions204and/or end caps206) may be dictated, for example, by the particular application (e.g., the type of floor100), the overall length L1of drain system200, the number of drains104(FIG. 1) and the like.

As one non-limiting example, and as illustrated inFIG. 2andFIG. 3, main body252may include one hub202(e.g., associated with drain104) (FIG. 1), a pair of elongated extensions204coupled (e.g., connected, attached or otherwise joined) to and extending in a straight line outwardly from opposed ends of hub202and a pair of longitudinally opposed end caps206coupled to terminating ends of extensions204.

As used herein, the terms “coupled,” “connected,” “attached,” and “joined” mean associated directly as well as indirectly. As a general example, a member A may be directly associated with a member B, or may be indirectly associated therewith, for example, via another member C. As a specific example, end cap206may be directly associated with an end of hub202, or may be indirectly associated with an end of hub202, for example, via one or more extensions204. It can be understood that not all relationships among the various disclosed components of main body252(e.g., hub202, extensions204and/or end caps206) are necessarily represented. Accordingly, couplings other than those depicted in the illustrated examples may also exist

Referring toFIG. 18, as another non-limiting example, main body252may include one elongated hub202(e.g., associated with drain104) (FIG. 1) and a pair of longitudinally opposed end caps206coupled to terminating ends of hub202.

Referring toFIG. 3, hub202may include hub top surface216a, each extension204may include extension top surface216band each end cap206may include end cap top surface216c. Hub top surface216a, extension top surfaces216band end cap top surfaces216cmay each define longitudinal sections of top surface216of main body252. Similarly, hub202may include hub drain channel220a, each extension204may include extension drain channel220band each end cap206may include end cap drain channel220c. Hub drain channel220a, extension drain channels220band end cap drain channels220cmay each define longitudinal sections of drain channel220of main body252.

As another non-limiting example, main body252may be a single longitudinal piece made of the same base material. For instance, main body252may be formed monolithically. In such an example, the overall length L1of drain system200and the number and location of drain opening222may be dictated, for example, by the particular application (e.g., the type of floor100), the number of drains104(FIG. 1) and the like.

Referring briefly toFIGS. 1 and 2, and with reference toFIGS. 6, 8, 10 and 12, drain channel220may include a lateral dimension, referred to herein as width W2. The width W2of drain channel220may be less than the width W1of main body252or the width W1of each individual component forming main body252(e.g., hub202, extension204and/or end caps206) (FIGS. 6, 8, 10 and 12). As one example, the width W2of drain channel220may be no more than fifty percent of the width W1of the main body252(or of each of hub202, extension204and/or end caps206). As another example, the width W2of drain channel220may be no more than twenty-five percent of the width W1of the main body252.

Referring toFIG. 2, in one example, drain channel220may be offset from the longitudinal axis A. As one example, drain channel220may be positioned on top surface216proximate first side212of main body252. In such an example, first horizontal surface226may include a lateral dimension less than a lateral dimension of second horizontal surface228.

The width W2of drain channel220may be less than a lateral dimension D1(e.g., a diameter) of drain opening222. As one example, the width W2of drain channel220may be approximately fifty percent of the dimension D1of drain opening222. With drain channel220being offset from the longitudinal axis A of drain system200, as illustrated inFIGS. 1 and 2, drain channel220may bisect (e.g., divide into two equal or non-equal parts) drain opening222.

Referring toFIGS. 1-4 and 18, drain system200may further include drain opening cover234, referred to herein as cover234. Cover234may be suitably sized and shaped to cover over any portion of drain opening222not in fluid communication with or intersected by drain channel220. As one example, cover234may include a semi-circular shape suitable to cover an open portion of drain opening222.

Referring toFIGS. 1 and 3, cover234may include cover top surface258(FIG. 3). Cover top surface258may be co-planar with and form a portion of top surface216of main body252. For example, cover top surface258may be co-planar with and form a portion of hub top surface216a. Cover top surface258may allow the construction of floor100(e.g., waterproof membrane108and/or floor covering114) to extend up to drain channel220over top of a portion of drain opening222, as illustrated inFIG. 1.

Referring toFIGS. 2 and 3, cover top surface258may include a straight edge266(FIG. 3). Edge266may be longitudinally aligned with a portion of drain channel220intersecting drain opening, as illustrated inFIG. 2. Thus, cover top surface258may define a portion of second horizontal surface228of main body252or of hub202.

Referring toFIG. 1, and with reference toFIGS. 6, 8, 10 and 12, drain channel220may include a thickness dimension, referred to herein as thickness T2. The thickness T2of drain channel220may be less than the thickness T1of main body252or the thickness T1of each individual component forming main body252(e.g., hub202, extension204and/or end caps206) (FIGS. 6, 8, 10 and 12). As one example, the thickness T2of drain channel220may be no more than ninety percent of the thickness T1of main body252(or of each of hub202, extension204and/or end caps206). As another example, the thickness T2of drain channel220may be no more than seventy-five percent of the thickness T1of main body252. As another example, the thickness T2of drain channel220may be no more than fifty percent of the thickness T1of main body252. As another example, the thickness T2of drain channel220may be no more than twenty-five percent of the thickness T1of main body252.

Referring toFIG. 4, and with reference toFIG. 1, drain system200may include grate224. Grate224may be positioned over top of drain channel220. Grate224may include a plurality of grate inlet openings240. Grate224may serve to prevent objects of a predetermined size from draining into drain channel220and into drain104. Grate224may be formed as a separate piece relative to main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206). In other words, grate224may not be formed integral to main body252, but may be an add-on piece.

Grate224may be suitably sized to substantially match drain channel220. For example, grate224may include a lateral dimension, referred to herein as width W3(FIG. 2), substantially equal to the width W2of drain channel220. Grate224may also include a longitudinal dimension (e.g., length) substantially equal to a longitudinal dimension (e.g., length) of drain channel220.

While the example ofFIG. 4illustrates a single elongated grate224covering the entire length of drain channel220, grate224may alternatively include a plurality of longitudinally aligned grate sections positioned over top of drain channel220(not explicitly illustrated).

Referring toFIG. 1, and with reference toFIG. 2andFIG. 3, drain system200may further include a plurality of grate supports236. Grate224may rest directly on and be supported by grate supports236. Grate supports236may be coupled to main body252. Grate supports236may be positioned within drain channel220. As one example, and as best illustrated inFIG. 2, grate supports236may be coupled to and supported by first sloped surface230and second sloped surface232. The number of grate supports236may be dictated by, for example, the length L1of drain system200.

Referring toFIG. 1, and with reference toFIG. 3andFIG. 14, drain system200may include a plurality of height adjusters238. Height adjusters238may be longitudinally spaced apart along drain channel220. Each grate support236may rest directly on and be supported by laterally aligned and spaced apart pairs of height adjusters238. Height adjusters238may adjust a vertical position (e.g., height) of grate support236and, thus, grate224(FIG. 1) relative to main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206). As illustrated inFIG. 1, height adjusters238may allow grate224to be positioned in a suitably co-planar relationship with the surface of floor100(e.g., with drain floor surface112).

Referring toFIG. 14, height adjusters238may be coupled to main body252within drain channel220. For example, height adjusters238may be operatively coupled to first sloped surface230and second sloped surface232. As one example, height adjuster238may include a fastener (e.g., a bolt) having a threaded shaft242and a head244. Threaded shaft242may be mechanically coupled to and project outwardly from a threaded hole (not explicitly illustrated) formed in first sloped surface230and second sloped surface232.

Referring toFIG. 17, and with reference toFIG. 14, grate support236may include a pair of laterally opposed recesses246formed in a bottom surface thereof. Recess246may be suitably sized to at least partially receive head244of height adjuster238(FIG. 14). Grate support236may include horizontal member248and a pair of laterally opposed shoulders250extending upwardly and outwardly from ends of horizontal member248. Recesses246may be formed in a bottom surface of horizontal member248. Recesses246may be located near the laterally opposed ends of horizontal member248(e.g., proximate shoulders250). Grate224may rest directly on and be supported by shoulders250. As one example, grate support236may be positioned between an adjacent pair of inlet openings240of grate224(FIG. 4).

Referring toFIGS. 2-8, 13 and 18, drain system200may further include a plurality of fastener holes254disposed through main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206). Fastener holes254may be longitudinally spaced apart along both sides (e.g., first side212and second side214) of main body252. For example, a plurality of longitudinally spaced apart fastener holes254may be formed through first horizontal surface226and a plurality of longitudinally spaced apart fastener holes254may be formed through second horizontal surface228, for example, spaced apart from laterally aligned fastener holes254. A fastener (not explicitly illustrated), such as a screw, may project through a respective fastener hole254to mechanically connect main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206) to subfloor102(FIG. 1).

Referring toFIGS. 2-8, 13 and 18, drain system200may further include adhesive channel256formed in main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206). For example, adhesive channel256may be a shallow groove or recess formed into top surface216. Adhesive channel256may be configured to receive adhesive bead124(e.g., glue or thinset cement) to adhere waterproof membrane108(FIG. 1) to top surface216of main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206).

Adhesive channel256may completely surround drain channel220and drain opening222of main body252. Adhesive channel256may extend longitudinally from proximate first end208to proximate second end210. Thus, adhesive channel256may run substantially the entire length L1of drain system200.

The components of drain system200including main body252(e.g., hub202, extensions204and/or end caps206) and/or grate224may be made of any suitable material. As one general, non-limiting example, drain system200may be made of plastic. As specific, non-limiting examples, drain system200may be made from PVC, ABS and the like. As another general, non-liming example, drain system200may be made of metal. As specific, non-limiting examples, drain system200may be made from galvanized steel, aluminum and the like. Other materials are also contemplated.

The components of drain system200may be manufactured by any suitable material forming process or fabrication operation. As one non-limiting example, main body252or each individual component forming main body252(e.g., hub202, extension204and/or end caps206) may be extruded. As another non-limiting example, main body252may be molded (e.g., injection molded). As another non-limiting example, main body252may be machined, for example, by a CNC machine. As another non-limiting example, main body252may be additively manufactured. Other manufacturing processes are also contemplated.

Referring toFIG. 3each component of main body252(e.g., hub202, extensions204and/or end caps206) may include connection feature264formed on at least one end thereof. Connection feature264serves to interconnect adjacent components of main body252in a straight line (e.g., along longitudinal axis A). As one example, hub202may include connection feature264at both longitudinally opposed (e.g., terminating) ends. As another example, extension204may include connection feature264at both longitudinally opposed (e.g., terminating) ends. As another example, end cap206may include connection feature264at one end.

Referring toFIGS. 15 and 16, connection feature264may include one of first interlocking feature268or second interlocking feature270. For example, first connection feature264a(FIG. 15) may include first interlocking feature268and second connection feature264b(FIG. 16) may include second interlocking feature270. First interlocking feature268and second interlocking feature270may operatively engage one another to connect the components of main body252. As one general, non-limiting example, connection feature264may include a tongue and groove connection.

As one example, and as best illustrated inFIG. 15, first interlocking feature268may include one or more tabs272(e.g., tongues or ridges) extending (e.g., longitudinally outward) from one end (e.g., first end208or second end210) of each component of main body252(e.g., hub202, extension204and/or end cap206). As one example, and as best illustrated inFIG. 16, second interlocking feature270may include one or more slots274(e.g., recesses or grooves) formed (e.g., longitudinally inward) in one end (e.g., first end208or second end210) of each component of main body252(e.g., hub202, extension204and/or end cap206). Slots274may be configured to receive tabs272for connection of adjacent components of main body252(e.g., hub202, extension204and/or end cap206) (FIGS. 2, 3 and 18).

As one example, and as illustrated inFIGS. 6 and 13, hub202may include first interlocking feature268(e.g., one or more tabs272) extending from first end260of hub202and second interlocking feature270(e.g., one or more slots274) formed in second end262of hub202. As another example, and as illustrated inFIG. 7, extension204may include first interlocking feature268extending from first end276of extension204and second interlocking feature270formed in second end278of extension204. As another example, and as illustrated inFIGS. 9 and 11, first end cap206amay include second interlocking feature270(e.g., one or more tabs272) formed in first end280of first end cap206aand second end cap206bmay include first interlocking feature268extending from first end280of second end cap206b.

As illustrated inFIGS. 2 and 3, and with reference toFIGS. 5, 7, 9 and 11, in one example, first interlocking feature268of first end260of hub202may engage second interlocking feature270of second end278of one extension204(e.g., first extension204a) (FIG. 3) to join hub202and first extension204a. First interlocking feature268of first end276of another extension204(e.g., second extension204b) (FIG. 3) may engage second interlocking feature270of second end262of hub202to join hub202and second extension204b. First interlocking feature268of first end276of first extension204amay engage second interlocking feature270of first end280of first end cap206ato join first extension204aand first end cap206a. First interlocking feature268of first end280of second end cap206bmay engage second interlocking feature270of second end278of second extension204bto join second extension204band second end cap206b.

Alternatively, the components of main body252(e.g., hub202, extension204and end caps206) may further be adhesively bonded together. As one example, hub202may include an adhesive (not explicitly illustrated) applied at one or both longitudinally opposed ends (e.g., first end260and/or second end262). As another example, extension204may include the adhesive applied at one or both longitudinally opposed ends (e.g., first end276and/or second end278). As another example, end cap206may include the adhesive applied at one end (e.g., first end280). Depending upon the configuration of main body252(e.g., the length of hub202and/or the number of extensions204) one of extension204or end cap206may be connected (e.g., directly connected) to hub202by the adhesive and/or end cap206may be connected to extension204by the adhesive.

Alternatively still, the use of connection features264(e.g., first interlocking feature268and second interlocking feature270) and the adhesive may be used to connect the components of main body252(e.g., hub202, extension204and end caps206). For example, first interlocking feature268and second interlocking feature270may make an initial connection between adjacent ends of hub202, extension204and/or end cap206and the adhesive may secure the connection between first interlocking feature268and second interlocking feature270.

While the example ofFIGS. 2-4illustrate main body252including only two extensions204(e.g., first extension204aand second extension204b) (FIG. 3), additional extensions204(not explicitly illustrated) may be interconnected, as necessary, to define length L1of main body252. Regardless of the number of extensions204used to form main body252, two end caps206(e.g., first end cap206aand second end cap206b) may be joined to longitudinally opposed terminating ends of the last extension204.

As illustrated inFIG. 18, and with reference toFIGS. 5, 7, 9 and 11, in another example, first interlocking feature268of first end260of hub202may engage second interlocking feature270of first end278of one end cap (e.g., first end cap206a) to join hub202and first end cap206a. First interlocking feature268of first end280of another end cap (e.g., second end cap206b) may engage second interlocking feature270of second end262of hub202to join hub202and second end cap206b.

Referring toFIGS. 5, 6 and 13, drain channel220may completely extend from first end260of hub202to second end262of hub202, for example, defining hub drain channel220a. Similarly, adhesive channel256may completely extend from first end260of hub202to second end262of hub202. Thus, as one example, hub202may include two laterally opposed and substantially parallel longitudinal sections of adhesive channels256, for example, formed in first horizontal surface226and second horizontal surface228, respectively, on either side of hub drain channel220a. One adhesive channel256may extend around a portion of a perimeter of drain opening222formed through hub202.

Referring toFIGS. 5 and 13, drain opening222may define a continuous (e.g., circular) side wall284extending from hub top surface216ato hub bottom surface218a. Flange286may extend circumferentially inward from side wall284proximate hub bottom surface218a. As one example, flange286may be a portion of hub bottom surface218. For instance, drain opening222at hub top surface216amay have a larger lateral dimension D1(e.g., diameter) than drain opening222at hub bottom surface218, for example, as defined by an internal lateral dimension (e.g., diameter) of flange286.

Referring toFIGS. 1 and 14, hub202may be connected to drain104such that drain channel220and drain opening222are in fluid communication with drain104. Drain opening222may be connected to any type of drain configuration. Drain104may include drain flange116extending circumferentially outward at a terminating (e.g., upper) end thereof, for example, a portion of drain104extending at least partially through subfloor102(FIG. 1). As one example, and as illustrated inFIG. 1, drain104may include drainpipe120including drain flange116. As another example, and as illustrated inFIG. 14, drain104may include drain fixture122including drain flange116. Drainpipe120may be coupled to drain fixture122.

Drain opening222may be configured (e.g., suitably sized and/or shaped) to fit around drain104. Drain flange116may rest on flange286of hub202within drain opening222. Drain fastener118may be operatively coupled around drain104(e.g., around drainpipe120or drain fixture122) opposite drain flange116with flange286positioned therebetween. Drain fastener118may be tightened to compress flange286between drain flange116and drain fastener118. As one example, drain fastener118may include a locking nut threadably coupled to an exterior of drain104(e.g., drainpipe120or drain fixture122).

Gasket128may be positioned between flange286and drain flange116. As one example, gasket128may include an annular rubber member suitably to seal an interface between drain flange116and flange286.

Referring toFIG. 3, and with reference toFIG. 1, cover234may rest on drain flange116(FIG. 1). Cover234may include at least one retaining tab290projecting outwardly from a semi-circular side wall292of cover234. Side wall284of drain opening222may include at least one retaining slot294formed therein. As one example, retaining tab290may extend downwardly (e.g., vertically) from cover top surface258along an exterior of side wall292of cover. Retaining slot294may extend downwardly (e.g., vertically) from hub top surface216awithin side wall284defining drain opening222. Upon cover234being positioned within drain opening222and resting on drain flange116(FIG. 1), retaining slot294may receive retaining tab290to retain cover234at a lateral position within drain opening222. In one example, cover234may include a pair of longitudinally opposed retaining tabs290and drain opening222may include a pair of longitudinally opposed retaining slots294(not visible inFIG. 3).

Referring toFIGS. 2-5, as one example, hub202may have a relatively shortened longitudinal dimension (e.g., length). For example, hub202may be suitably sized to fit over and be coupled to drain104. In such an example, one or more extensions204may form the majority of the length L1of main body252. For example, extensions204may extend outwardly in a straight line from longitudinally opposed ends (e.g., first end260and second end262) of hub202a desired distance and end caps206may be coupled to extensions204. Further, in such an example, drain opening222may be pre-formed, for example, during a manufacturing (e.g., molding) process. Drain opening222may be formed substantially at a center (e.g., a longitudinal center and lateral center) of hub202.

Referring toFIGS. 13 and 18, as another example, hub202may have an elongated longitudinal dimension (e.g., length). In such an example, hub202may form the majority of the length L1of main body252. For example, hub202may extend outwardly in a straight line a desired distance. Further, in such an example, drain opening222may be formed (e.g., machined) post-manufacturing and pre-installation. Drain opening222may be formed at any longitudinal location of hub202, for example, as dictated by the location of drain104(FIG. 1). Drain opening222may still be formed substantially at the lateral center of hub202.

Referring toFIGS. 7 and 8, drain channel220may completely extend from first end276of extension204to second end278of extension204, for example, defining extension drain channel220b. Similarly, adhesive channel256may completely extend from first end276of extension204to second end278of extension204. Thus, as one example, extension204may include two laterally opposed and substantially parallel longitudinal sections of adhesive channels256, for example, formed in first horizontal surface226and second horizontal surface228, respectively, on either side of extension drain channel220b.

Referring toFIGS. 9 and 10, drain channel220may extend from first end280of first end cap206ato proximate second end282of first end cap206a, for example, defining end cap drain channel220c. Similarly, adhesive channel256may extend from first end280of first end cap206ato proximate second end282of first end cap206a. Thus, as one example, first end cap206amay include two laterally opposed and substantially parallel longitudinal sections of adhesive channels256, for example, formed in first horizontal surface226and second horizontal surface228, respectively, on either side of end cap drain channel220cand a lateral adhesive channel256proximate an end of end cap drain channel220c. End cap top surface216cmay also include third horizontal surface288extending laterally between first horizontal surface226and second horizontal surface228. Third horizontal surface288of first end cap206amay form an end of (e.g., a closing of) end cap drain channel220c(e.g., first end cap drain channel). The lateral adhesive channel256may be formed in third horizontal surface288.

Referring toFIGS. 11 and 12, drain channel220may extend from first end280of second end cap206bto proximate second end282of second end cap206b, for example, defining end cap drain channel220c. Similarly, adhesive channel256may extend from first end280of second end cap206bto proximate second end282of second end cap206b. Thus, as one example, second end cap206bmay include two laterally opposed and substantially parallel longitudinal sections of adhesive channels256, for example, formed in first horizontal surface226and second horizontal surface228, respectively, on either side of end cap drain channel220cand a lateral adhesive channel256proximate an end of end cap drain channel220c. End cap top surface216cmay also include third horizontal surface288extending laterally between first horizontal surface226and second horizontal surface228. Third horizontal surface288of second end cap206bmay form an end of end cap drain channel220c(e.g., second end cap drain channel). The lateral adhesive channel256may be formed in third horizontal surface288.

Referring toFIGS. 2, 9 and 11, third horizontal surface288may allow the construction of floor100(e.g., waterproof membrane108and floor covering114) (FIG. 1) to extend up to the end of drain channel220. Third horizontal surface288of each end cap206(e.g., first end cap206aand second end cap206b) may form longitudinally opposed ends of (e.g., a closing of) drain channel220.

While the examples disclosed herein illustrate drain system200including only a linear main body252(e.g., at least hub202, at least one extension204and at least two end caps206), additional linear bodies (e.g., at least one additional extension204) coupled to and/or extending outwardly (e.g., at a right angle) from main body252are also contemplated (not explicitly illustrated). For example, drain system200may include one or more ninety-degree connectors or one or more T-shaped connectors to interconnect extensions204at substantially right angles (not explicitly illustrated). As one example, interconnecting two extensions204with a ninety-degree connector may form an L-shaped drain system200. As another example, interconnecting three extensions204with two ninety-degree connectors may form a U-shaped drain system200. As another example, interconnecting four extensions204with four ninety-degree connectors may form a square-shaped drain system200. As another example, interconnecting three extensions204with a T-shaped connector may form a T-shaped drain system200. Other configurations are also contemplated, for example, as dictated by the type of floor100and/or the drainage needs of floor100. Any angle connectors (e.g., ninety-degree connector and/or T-shaped connector) may similarly include a V-shaped drain channel forming a corner section of drain channel220(e.g., in fluid communication with extension drain channel220b) of main body252, adhesive channels256, fastening holes254and/or height adjusters238.

Referring toFIG. 19, and with reference toFIGS. 2-4 and 18, one embodiment of method, generally designated300, for manufacturing main body252of drain system200is disclosed. Modifications, additions, or omissions may be made to method300without departing from the scope of the present disclosure. Method300may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.

Method300may begin with the step of forming hub202, as shown at Block302. Hub202may include a V-shaped hub drain channel220aand drain opening222. Drain opening222may at least partially intersect and be in fluid communication with hub drain channel220a.

Method300may further include the step of forming a pair of end caps206(e.g., first end cap206aand second end cap206b), as shown at Block304. Each end cap206may include a V-shaped end cap drain channel220c.

Method300may further include the step of forming at least one extension204, as shown at Block306. Extension204may include a V-shaped extension drain channel220b.

In one example, forming hub202(Block302) may include molding a base material (not explicitly illustrated) to form hub drain channel220a(e.g., first sloped surface230and second sloped surface232) and drain opening222in hub202, as shown at Block308. Molding the base material may also form hub top surface216a(e.g., first horizontal surface226and second horizontal surface228), adhesive channel256, fastener holes254and/or holes for height adjusters238.

As illustrated inFIGS. 2-4, a molded hub202may include a relatively small longitudinal dimension (e.g., length) relative to the overall length L1of main body252. In such an example, one or more extensions204may be configured to connect to longitudinal ends (e.g., first end260or second end262) of hub202. Thus, extensions204may define a substantial majority of the overall length L1of main body252. Further, in such an example, each end cap206may be configured to connect to one of an end of hub202or an end of extension204(e.g., extension204may be configured to connect between hub202and one of the pair of end caps206). During construction of floor100having drain system200, hub202may be located over and connected to drain104(FIG. 1). Extensions204and end caps206may be connected to and extend from hub202to construct main body252as dictated by, for example, the final configuration of drain system200and/or the construction of floor100(FIG. 1).

In another example, forming hub202(Block302) may include extruding a base material to form hub drain channel220a(e.g., first sloped surface230and second sloped surface232) in hub202, as shown at Block310. Extruding the base material may also form hub top surface216a(e.g., first horizontal surface226and second horizontal surface228) and/or adhesive channel256.

Forming hub202(Block302) may further include machining drain opening222through hub202, as shown at Block312. Fastener holes254and/or holes for height adjusters238may also be machined through hub202.

As illustrated inFIG. 18, an extruded hub202may include a relatively large longitudinal dimension (e.g., length) relative to the overall length L1of main body252. Thus, hub202may define a substantial majority of the overall length L1of main body252. In such an example, each end cap206may be configured to connect to the longitudinally opposed ends (e.g., first end260and second end262) of hub202. During construction of floor100having drain system200, the longitudinal dimension of hub202may be cut to a desired length as dictated by, for example, the final configuration of drain system200and/or the construction of floor100(FIG. 1). Drain opening222may be formed (e.g., machined) through hub202at a suitable location as dictated by the location of drain104(FIG. 1) to be located over and connected to drain104.

Forming end caps206(Block304) may include molding a base material to form end cap drain channel220c(e.g., first sloped surface230and second sloped surface232), end cap top surface216c(e.g., first horizontal surface226, second horizontal surface228and third horizontal surface288), adhesive channel256, fastener holes254and/or holes for height adjusters238.

Similarly, forming extensions204(Block306) may include molding a base material to form extension drain channel220b(e.g., first sloped surface230and second sloped surface232), extension top surface216b(e.g., first horizontal surface226and second horizontal surface228), adhesive channel256, fastener holes254and/or holes for height adjusters238.

Other techniques for forming the components of main body252(e.g., hub202, extensions204and/or end caps206) are also contemplated.

Referring toFIG. 20, and with reference toFIGS. 1-4 and 18, one embodiment of method, generally designated400, for constructing floor100with a linear drain system200is disclosed. Modifications, additions, or omissions may be made to method400without departing from the scope of the present disclosure. Method400may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.

Method400may begin with the step of locating drain opening222of main body252over drain104, as shown at Block402. As one example, hub202including a pre-formed drain opening222(e.g., a molded hub202) may be positioned on subfloor102such that at least a portion of drain104is disposed within drain opening222. As another example, hub202(e.g., an extruded hub202) may be positioned on subfloor102over drain104and drain opening222may be formed (e.g., machined) through hub202aligned with drain104.

Method400may further include the step of coupling drain104to main body252(e.g., to hub202), as shown at Block404. As one example, flange286of hub202may engage drain flange116of drain104. Drain fastener118may be coupled to drain104and tightened to compress flange286between drain flange116and drain fastener118.

Method400may further include the step of coupling main body252of drain system200to subfloor102, as shown at Block406. As one example, main body252may be fastened (e.g., by screws) to subfloor102. The total number of components of main body252(e.g., hub202, extensions204and end caps206) and the overall length L1of main body252may be dictated by, for example, the type and size of floor100, the drainage needs of floor100and/or the final configuration of drain system200.

Method400may further include the step of laying underlayment106over subfloor102, as shown at Block408. Underlayment106may extend up to (e.g., abut) laterally opposed sides (e.g., first side212and second side214) of main body252or of each individual component forming main body252(e.g., hub202, extensions204and end caps206). Similarly, underlayment106may extend up to (e.g., abut) longitudinally opposed ends (e.g., first end208and second end210) of main body252. As described herein above, underlayment106may include (e.g., be formed with) a slope directed downwardly toward main body252.

Optionally, one or more waterproofing membranes108may be laid over and coupled (e.g., adhered) to subfloor102and/or underlayment106. Waterproofing membranes108may be laid over and coupled to subfloor102may extend to sides and ends of main body252. Waterproofing membranes108may be laid over and coupled to underlayment106may extend to sides and ends of drain channel220formed in top surface216of main body252.

Method400may further include the step of laying floor covering114(e.g., tile110) over underlayment106(or waterproofing membrane108), as shown at Block410. Floor covering114may define drain floor surface112of floor100. Floor covering114may extend up to (e.g., laid adjacent to) laterally opposed sides of drain channel220of main body252or of each individual component forming main body252(e.g., hub drain channel220a, extension drain channel220band end cap drain channel220c). Similarly, floor covering114may extend up to (e.g., laid adjacent to) longitudinally opposed ends of drain channel220of main body252. As described herein above, underlayment106may include (e.g., be formed with) a slope directed downwardly toward main body252. As described herein above, the resulting drain floor surface112formed by floor covering114may include a slope matching the slope formed by underlayment106to direct water to drain channel220.

Method400may further include the step of positioning grate224over drain channel220, as shown at Block412. As one example, grate224may be supported by a plurality of grate supports236coupled to main body252within drain channel220. Each grate support236may be coupled to a pair of height adjusters238. Height adjusters238may be adjustably coupled to main body252within drain channel220(e.g., to first sloped surface230and second sloped surface232) to adjust a vertical position (e.g., height) of grate224relative to main body252. Grate224may be positioned to be substantially co-planar with the surface of floor covering114to define a portion of drain floor surface112.

Although various embodiments of the disclosed systems and methods have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.