Abstract:
A channel drain assembly includes a channel drain and a grate. The channel drain includes a body having at least one sidewall and a bottom wall, a flange extending about a periphery of the body, and a drain pipe. The grate is positionable within the body and includes at least one side wall and a top wall that has a plurality of apertures extending therethrough. When the grate is positioned within the body a first flow path and a second flow path are formed that provide a path for fluid to flow into the channel drain and out the drain pipe. The first flow path is formed across the plurality of apertures, while the second flow path is formed between the at least one side wall of the grate and at least one sidewall of the body.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to channel drains, and, more specifically, to a channel drain having an integral weep path and a method of installing a channel drain having an integral weep path. 
         [0003]    2. Related Art 
         [0004]    Floor drains, including channel drains generally, are well known in the art. Floor drains could be installed through the flooring of a room to allow water to flow along the floor and exit through the drain. In some instances the floor could include a separate housing that the floor drain is installed through, e.g., a bathtub or a residential shower enclosure, while in other embodiments the floor drain could be installed directly in the floor with a tile or ceramic layer flush with the drain. Regardless, in both instances a sub-drain must be installed along with the floor drain, creating a weep path for excess fluid to flow along and to an exit pipe. 
         [0005]      FIG. 1  is a cross-sectional view of an exemplary prior art floor drain that includes a sub-drain. The floor drain assembly  10  includes a channel drain  12  connected to a first drain pipe  14  and a sub-drain  16 . The sub-drain  16  is installed in a subfloor  18 . A backerboard  20  is installed on top of the subfloor  18  and over the sub-drain  16 , and a waterproof membrane  22  is installed over the backerboard  20 . The channel drain  12  is installed over the waterproof membrane  22  and the sub-drain  16 , such that water drains through the channel drain  12 , the connected first drain pipe  14 , and into the sub-drain  16 , e.g., in the direction of arrows A. The channel drain  12  is secured with the sub-drain  16  by a clamping flange  24  and a sub-drain seal  26 . The clamping flange  24  and the sub-drain seal  26  are positioned between the first drain pipe  14  of the channel drain  12  and the waterproof membrane  22  and the backerboard  20 . This arrangement creates two different fluid flow paths. First, the floor drain assembly  10  allows fluid to flow through the channel drain in the direction of arrows A and into the sub-drain  16  without contacting the waterproof membrane  22 . Second, the floor drain assembly  10  allows fluid that does not reach the channel drain to flow under the channel drain along arrows B (known as a weep path) and into the sub-drain  16 . As shown, both fluid flows A and B flow to the sub-drain  16  and through the second drain pipe  28  connected to the sub-drain  16 , and to the sewer system. 
         [0006]    The floor drain assembly  10  of the prior art requires a sub-drain to be installed separate from, and in addition to, a channel drain. Accordingly, what would be desirable, but has not yet been provided, is a system and method of installing a floor drain that addresses the foregoing limitations of existing floor drains. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention relates to a channel drain assembly including a channel drain and a grate. The channel drain includes a body having at least one sidewall and a bottom wall, a flange extending about a periphery of the body, and a drain pipe. The grate is positionable within the body and includes at least one side wall and a top wall that has a plurality of apertures extending therethrough. When the grate is positioned within the body a first flow path and a second flow path are formed that provide a path for fluid to flow into the channel drain and out the drain pipe. The first flow path is formed across the plurality of apertures, while the second flow path is formed between the at least one side wall of the grate and at least one sidewall of the body. 
         [0008]    In one embodiment, the drain pipe extends from the bottom wall of the channel drain body. In another embodiment, the channel drain also includes a basin extending from the bottom wall of the body, and the drain pipe extends from a side of the basin. 
         [0009]    The present invention further relates to a method of installing a channel drain assembly. A channel drain is provided that has a body, a flange extending about a periphery of the body, and a drain pipe. A grate is also provided that is positionable within the body and includes at least one side wall and a top wall, the top wall having a plurality of apertures extending therethrough. A location for installation of the drain pipe is determined and a subfloor is installed at the installation location. A backerboard is then installed on top of the subfloor. A hole dimensioned slightly larger than the dimensions of the channel drain body is cut through the subfloor and the backboard. The channel drain body is then placed into the hole such that the flange rests on the backerboard. Next, a hole dimensioned to match the dimensions of the channel drain body is cut from a waterproof membrane. Adhesive is applied to the flange, and the waterproof membrane is placed over the channel drain with the waterproof membrane hole positioned over the channel drain body. The waterproof membrane is then secured to the flange. The grate is then positioned within the body and tile is installed on the waterproof membrane about the grate. 
         [0010]    In another aspect, a tile plug template that is positionable within the channel drain body may be provided. The hole through the subfloor and the backerboard, and the hole through the waterproof membrane could be dimensioned and cut with the tile plug template. In still another aspect, the tile plug template could be positioned within the channel drain body prior to placing the waterproof membrane over the channel drain with the waterproof membrane hole positioned over the channel drain body, and removed after securing the waterproof membrane to the flange. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The foregoing features of the invention will be apparent from the following Detailed Description of the Invention, taken in connection with the accompanying drawings, in which: 
           [0012]      FIG. 1  is a cross-sectional view of a prior art floor drain assembly; 
           [0013]      FIG. 2  is a perspective view of a channel drain assembly of the present disclosure; 
           [0014]      FIG. 3  is an exploded perspective view of the channel drain assembly of  FIG. 2 ; 
           [0015]      FIG. 4  is a top view of the floor drain assembly of  FIG. 2 ; 
           [0016]      FIG. 5  is a perspective view of the channel drain assembly of  FIG. 2  including floor elements; 
           [0017]      FIG. 6  is a cross-sectional view of the floor drain assembly of  FIG. 5  taken along line  6 - 6 ; 
           [0018]      FIG. 7  is an alternate embodiment of the channel drain assembly of the present disclosure; 
           [0019]      FIG. 8  is a perspective view showing installation of a channel drain of the present disclosure; and 
           [0020]      FIG. 9  is a perspective view showing installation of the channel drain assembly of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    The present invention relates to a channel drain having an integral weep path. 
         [0022]      FIG. 2  is a perspective view of a channel drain assembly  100  having an integral weep path, and  FIG. 3  is an exploded perspective view of the channel drain assembly of  FIG. 2 . The channel drain assembly  100  includes a channel drain  102  including a drain body  104 , a membrane flange  106 , and a drain pipe  108 . The drain body  104  includes one or more sidewalls  105   a , and a bottom wall  105   b . A drain pipe  108  extends from the bottom wall  105  of the drain body  104 , and allows water to flow out from the channel drain  102 . The flange  106  extends outwardly from an upper periphery of the drain body  104 . The channel drain assembly  100  further includes a grate  110  that includes one or more grate sidewalls  112 , a top wall  113 , a plurality of stand-offs  114 , and a primary drain path  116  that is defined by a plurality of removed sections extending through the top wall  113 . The grate  110  is dimensioned similar to that of the drain body  104 , such that the grate  110  can be placed on the channel drain  102  with the stand-offs  114  extending into the drain body  104 . 
         [0023]      FIG. 4  is a top view of the floor drain assembly of  FIG. 2 . When the grate  110  is positioned on the channel drain  102  a small gap, or integral weep path,  118  is formed between one or more of the grate sidewalls  112  and one or more of the sidewalls  105   a  of the drain body  104 . The integral weep path  118  permits fluid that does not flow through the primary drain path  116 , e.g., through the grate  110 , to flow along a secondary drain path to the drain body  104 , e.g., along the flange  106  and through the integral weep path  118 . Accordingly, the channel drain assembly  100  includes two integral drain paths by way of the primary drain path  116  and the weep path  118 . 
         [0024]      FIG. 5  is a perspective view of the channel drain assembly of  FIG. 2  showing floor elements. When installed in a floor, the channel drain assembly  100  requires a plurality of floor elements to be installed along with the channel drain assembly  100 . These floor elements include a waterproof membrane  120 , a tile adhesive  122 , and tile  124 . The waterproof membrane  120  is positioned and installed on to the top of, and extending outwardly from, the membrane flange  106 . The waterproof membrane  120  extends about the entire periphery of the flange  106 , and can extend out from the membrane flange  106  varying distances dependent upon an installer&#39;s desires. The waterproof membrane  120  provides a layer of waterproof protection such that fluid that does not drain through the primary drain path  116 , e.g., through the grate  110 , could flow along the waterproof membrane  120 , through the integral weep path  118 , into the drain body  104 , and out the drain pipe  108 . As mentioned previously, the distance that the waterproof membrane  120  extends from the channel drain assembly  100  could be based on the purpose of installation. For example, where the channel drain assembly  100  is being used for a multi-shower room, e.g., a fitness center communal shower area, the waterproof membrane  120  could extend several feet. However, on the other hand, if the channel drain assembly  100  is to be installed in a personal shower area then it could only extend a couple feet from the drain body  104 . The tile adhesive  122  is placed on top of the waterproof membrane  120  for securing the floor tiles  124  in place. The tile adhesive  122  could be mastic or thinset mortar. The floor tiles  124  are installed on top of the tile adhesive, with each floor tile  124  bonded to one another with grout  126 . In such an arrangement, the floor tiles  124  are bonded to the waterproof membrane  120  by the tile adhesive  122 . The floor tiles  124  could be ceramic tiles, or any other tile that is known in the art. Generally, when installed, the floor tiles  124  will be at the same height as the top of the grate  110  such that a flat transition is created from the floor tiles  124  to the grate  110 . In some embodiments, the floor tiles  124  adjacent the grate  110  could be secured to the grate  110  by grout  126 . 
         [0025]      FIG. 6  is a cross-sectional view of the floor drain assembly of  FIG. 5  taken along line  6 - 6 . The drain body  104  is generally installed in a floor that includes a backerboard  128  and a subfloor  130 . As illustrated in  FIG. 6 , the drain body  104  is seated within the backerboard  128  and subfloor  130 , such that the membrane flange  106  rests on the backerboard  128 . The waterproof membrane  120  is installed over the backerboard  128  and the membrane flange  106 . As can bee seen in  FIG. 6 , the weep path  118  is formed between the sidewalls  105   a  of the channel drain  102  and the grate sidewalls  112 . Thus, fluid can flow along the waterproof membrane  120 , through the weep path  118 , and into the drain body  104 . The stand-offs  114  elevate the grate sidewalls  112  from the drain body  104  providing space for fluid to flow. 
         [0026]    Additionally, the stand-offs  114  may elevate the grate  110  so that the top wall  113  is substantially co-planar with the floor tile  124 . Furthermore, the floor tile  124  and the waterproof membrane  120  are installed at a slight incline so that fluid will flow into the first flow path  116  and the weep path  118 , respectively, instead of pooling. 
         [0027]    The drain body  104  could be constructed in various shapes. For example, the drain body  104  could be rectangular, as illustrated in  FIGS. 2-6 , circular, square, or any other geometric configuration known in the art. Similarly, the grate  110  would be of similar geometric configuration. 
         [0028]      FIG. 7  is a perspective view of an alternate embodiment of the channel drain assembly of the present invention. The channel drain assembly  200  includes a channel drain  202  including a drain body  204 , a membrane flange  206 , and a drain pipe  208 . The drain body  204  includes one or more sidewalls (not shown), a bottom wall  205 , and a basin  207  extending from the bottom wall  205 . A drain pipe  208  extends horizontally from the basin  207  and allows water to flow out from the channel drain  202 . This arrangement permits fluid to flow out from the drain pipe  208  and generally parallel with a floor that the channel drain assembly  200  is installed in. The flange  206  extends outwardly from an upper periphery of the drain body  204 . The channel drain assembly  200  further includes a grate  210  that includes one or more grate sidewalls  212 , a top wall  213 , a plurality of stand-offs (not shown), and a primary drain path  216  that is defined by a plurality of removed sections extending through the top wall  213 . The grate  210  is dimensioned similar to that of the drain body  204 , such that the grate  210  can be placed on the channel drain  202  with the stand-offs  214  extending into the drain body  204 . The channel drain assembly  200  illustrated in  FIG. 7  functions and is installed substantially similarly to the channel drain assembly  100  of  FIGS. 2-6 . Such functionality and installation need not be repeated. 
         [0029]      FIG. 8  is a perspective view showing installation of a channel drain of the present disclosure, and  FIG. 9  is a perspective view showing a channel drain of the present disclosure partially installed. To install the channel drain  102 , an installation location is first selected. A subfloor  130  and backerboard  128  are installed at the installation location according to local codes. A cardboard tile plug  134 , which is shaped to generally match the geometric shape of the drain body  104 , is provided and used as a template to mark a rectangular cut-line on the backerboard  128 . The cut-line should be sized slightly larger in width and length dimensions, e.g., ¼″, than the channel drain  102  to be installed. This extra space provides clearance for the channel drain  120 . An installer then cuts a hole  132  in the backerboard  128  and the subfloor  130  according to the cut-line and template. The square hole  132  will act as a housing for the channel drain  102 . 
         [0030]    A bead of silicone caulking is applied to the underside of the membrane flange  106 , and the channel drain  102  is then installed such that the drain body  104  is inserted into the hole  132  and the membrane flange  106  rests on and are bonded to the backerboard  128 . An installer then cuts a piece of waterproof membrane  120  to a desired size and removes a portion at the center of the waterproof membrane  120  according to the cardboard tile plug template  134 . This removed portion is sized to match the length and width of the drain body  104 . An adhesive  136  is applied to the membrane flange  106 . The cardboard tile plug  134  is then placed in the drain body  104  and the waterproof membrane  120  is placed over the channel drain  102 , such that the cardboard tile plug  134  is positioned within the removed portion of the waterproof membrane  120 . The waterproof membrane  120  is then pressed down and bonded with the membrane flange  106  by the adhesive  136 . The waterproof membrane  120  could also be installed according to a manufacturer&#39;s instructions. 
         [0031]    The tile adhesive  122 , e.g., thinset mortar, is then applied to the waterproof membrane  120 . Once the tile adhesive  122  is completely applied, the floor tiles  124  are installed on the tile adhesive  122 . The floor tiles  124  may also be installed with grout  126  applied between the floor tiles  124 . Subsequently, the tile plug  135  is then removed and the grate sidewalls  112  is placed into the channel drain  102  and could be bonded to the floor tiles  124  by grout  126 . 
         [0032]    Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof. What is desired to be protected is set forth in the following claims.