Abstract:
An overflow system in the bathtub has an overflow port and has a drain pipe in connection with the overflow port. A threaded flange has a stub shoulder on one end which is fitted into a circular sleeve on the overflow port. The threaded flange has exterior threads on its outer surface and a thin diaphragm secured to the end thereof opposite to the stub shoulder. A large sealing washer embraces the outside of the circular flange on the overflow port and extends partially over the threads of the threaded flange. A large internally threaded nut is threadably mounted on the outer end of the threaded flange and compresses the sealing washer against a vertical flange on the port to seal the connection between the threaded flange and the port. A decorative cap is frictionally snapped into engagement with protrusions on the outer surface of the nut. The cap can be removed when needed to permit the plumber to gain access to the diaphragm to cut it open for fluid flow after the system has been tested for leaks, or put in place after the cut takes place.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 10/674,862, filed Sep. 30, 2003 now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 10/222,062, filed Aug. 16, 2002, now U.S. Pat. No. 6,637,050, and a continuation-in-part of U.S. patent application Ser. No. 10/229,533, filed Aug. 28, 2002, now U.S. Pat. No. 6,675,406, which is a continuation of abandoned U.S. patent application Ser. No. 09/593,724, filed Jun 13, 2000. This application is also a continuation-in-part of pending U.S. patent application Ser. No. 10/732,726, filed Dec. 10, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/229,533, filed Aug. 28, 2002, now U.S. Pat. No. 6,675,406, which is a continuation of abandoned U.S. patent application Ser. No. 09/593,724, filed Jun. 13, 2000, U.S. patent application Ser. No. 10/732,726 also being a continuation-in-part of U.S. patent application Ser. No. 09/954,420, filed Sep. 17, 2001, now U.S. Pat. No. 6,691,411. The entire disclosures of the above-referenced patents and applications are incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     In new building construction, plumbers prefer not to install finished closure valves in the bottom of bathtubs, or install finished decorative plate over an overflow outlet of the bathtub until the project is finished because these elements will be often damaged during construction. Further, the plumbing for all outlets needs to be checked for leaks which involves filling a vent for the drain until the water level in the plumbing rises above the bathtub so that the inspector can determine whether any of the plumbing leaks. The bottom drain of the bathtub is plugged and some sort of seal plate is used to block the outlet port during testing. 
     Existing overflow plates have a center opening. There are either two or four small screw holes in the plate adjacent the center opening wherein two of the holes are used to secure the plate to the plumbing fixture. In some cases, a fitting is used so that the screw hole is located directly in the middle of the access hole that becomes an obstacle during testing. The testing procedure usually involves placing a balloon through the large center opening into a drain pipe located in the wall. The pipe is sealed when the balloon is inflated. 
     A more recent version of an overflow assembly is shown in the U.S. Pat. No. 5,890,241 to Ball (“Ball”), which is incorporated by reference herein. Ball discloses a flexible diaphragm that is imposed over an overflow drain pipe. A cap is also provided that allows fluid to flow into the overflow pipe. The diaphragm seals the overflow pipe when the system is being tested for leaks. Following the test, the diaphragm is cut or slashed to open the overflow port to allow fluid flow. While this device serves the intended function, it is expensive to make and cumbersome to assemble. 
     It is, therefore, a principal object of the invention to provide a method and a means for an overflow assembly for bathtubs and the like that will safeguard the overflow system during construction, prepare the overflow system for testing, and facilitate the final installation of bathtub hardware. 
     A further object of the invention is to facilitate the testing procedure of the overflow system before final installation has taken place, and to permit the assembly of parts without the use of screws, screw holes, and the like. 
     A still further object of the invention is to provide an overflow fitting that allows a user to install the overflow fitting without using solvent cement. 
     These and other objects will be apparent to those skilled in the art. 
     SUMMARY OF THE INVENTION 
     An overflow system of a bathtub generally includes an overflow port that is associated with a drain pipe. The overflow port includes a threaded flange with a stub shoulder on one end that is fitted onto a circular sleeve. The threaded flange has threads on its outer surface and a thin diaphragm secured to the end thereof opposite the stub shoulder. A large sealing washer cooperates with the outside of the circular flange on the overflow port and extends partially over the threads of the flange. A large internally threaded nut is threadably mounted on the outer end of the threaded flange and compresses the sealing washer against a vertical flange on the overflow port to seal the connection between the threaded flange and the overflow port. A decorative cap is frictionally engaged onto protrusions located on the outer surfaces of the nut. The cap can be removed if needed to permit a plumber to gain access to the diaphragm to cut it open for fluid flow after the plumbing system has been tested for leaks, or put in place after the cut takes place. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial perspective view of a conventional bathtub environment utilizing the invention of this application; 
         FIG. 2  is a section view taken on line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is a perspective exploded view of an overflow assembly of one embodiment of the present invention; 
         FIG. 4  is a cross sectional view of the assembled components of  FIG. 3 ; 
         FIG. 5  is a perspective view showing a pierced diaphragm; 
         FIG. 6  is a sectional view of a conventional bathtub environment utilizing the device of another embodiment of the invention; 
         FIG. 7  is a side view of the device of the embodiment of the invention shown in  FIG. 6 ; 
         FIG. 8  is a front view of the device of the embodiment of the invention shown in  FIG. 6 ; 
         FIG. 9  is an exploded perspective view of the device of the embodiment of the invention shown in  FIG. 6 ; 
         FIG. 10  is a perspective view of the installation of the embodiment of the invention shown in  FIG. 6 ; 
         FIG. 11  is a perspective view of an overflow plate according to one embodiment of the present invention; 
         FIG. 12  is a sectional top view of the assembly according to one embodiment of the present invention; 
         FIG. 13  is a sectional top view of the assembly according to another embodiment of the present invention; 
         FIG. 14   a  is a sectional side view of the assembly according to yet another embodiment of the present invention; 
         FIG. 14   b  is a partial front view of the assembly of  FIG. 14   a ; and 
         FIG. 15  is a sectional side view of the assembly according to yet another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIGS. 1 and 2 , a conventional bathroom structure  10  has a floor  12  and a hollow wall  14  with a wall opening  16  therein. A conventional bathtub (“tub”)  18  has sidewalls that  22  extend upwardly from a base  20  as does an end wall  24 . The end wall  24  extends upwardly from a bottom surface  26 , perpendicular to the side walls  22 . 
     A conventional drain port  28  is located in the bottom surface  26 . A conventional overflow port  30  is located in the end wall  24  ( FIG. 2 ). A vertical drain pipe  34  extends downwardly from drain port  28  and an overflow drain pipe  34  extends downwardly from overflow port  30 . A horizontal pipe  36  connects pipes  32  and  34 . A drain pipe  38  extends downwardly from the junction between pipes  34  and  36 . 
     A conventional vent pipe  40  is located within the hollow wall  14 . Pipe  42  interconnects the vent pipe  40  and the upper end of overflow drain pipe  34  ( FIG. 2 ). Conventional water supply pipes  44  extend through hollow wall  14  and are connected to valve  46  which is interconnected to conventional control member  48  and faucet  50 . 
       FIGS. 3 and 4  show a radial flange  52  formed on the upper end of overflow drain pipe  34  and has a center opening or port  54 . Water can flow through center opening  54  into overflow drain pipe  34 . A sleeve  56  extends longitudinally outwardly from the perimeter of opening  54  forming a surface on its inner diameter. 
     A hollow cylindrical fitting  58  has a hollow cylindrical shoulder  60  on its inner end, a threaded outer surface  62 , and a thin plastic diaphragm  64  sealed across its outer end. The shoulder  60  has an outer diameter that can be manually frictionally inserted within the surface of the inner diameter of sleeve  56  to create sufficient frictional force to resist opposing force applied by fluid pressure. 
     A pliable sealing ring or washer  66  has a center bore  67  which frictionally receives the exterior surface of fitting  58  to engage the radial flange  52  of port  54  to seal the connection between sleeve  56  and shoulder  60 . The longitudinal thickness of washer  66  is less than the longitudinal thickness of fitting  58  so that some of the threaded surface  62  adjacent the diaphragm  64  is exposed when the washer  66  is mounted on fitting  58  in the position described above. A nut element  68  has a threaded center bore  70  which is compatible with the threaded outer surface  62  of fitting  58 . When the nut element  68  is tightened on threaded portion  62 , the washer  66  is in tight engagement with flange  52  of port  54 . The outer periphery  72  of nut element  68  has a series of radially extending lugs  74  which frictionally detachably engage the inner surface of flange  76  of cap  78 . The nut element  68  can be tightened on washer  66  either as positioned within cap  78 , or before cap  78  and the nut element  68  are engaged. A notch  80  is located in flange  76  and is adapted to receive overflow water from tub  18  when required to do so. Notch  80  is normally in a 6 o&#39;clock position on flange  76 .  FIG. 4  depicts the apparatus described above in an assembled state. 
     It is important to note that diaphragm  64  is of plastic material, as is fitting  58 , and is preferably integrally formed with fitting  58  wherein diaphragm  64  and fitting  58  are one unitary component. The diaphragm  64  is a thin circular plate disk that is joined to fitting  58  by its outer peripheral edge engaging the outer peripheral edge of the fitting  58 . If the two components are not molded as one unitary structure, the diaphragm  64  could be connected by fusing, hermetically sealing, or by otherwise rigidly attaching by its outer peripheral edge to the rearward outer peripheral edges of the fitting  58  by a suitable adhesive. No screws or the like are either required or desired. 
     A second embodiment of the invention can be seen in  FIG. 6 . A one-piece overflow fitting  60 A is shown attached to second vertical drain pipe  34 A. A portion of the overflow fitting  60 A passes through overflow port  30 . 
     With reference to  FIGS. 7-9 , the overflow fitting  60 A is shown that has an overflow pipe  62 A with an inverted L-shape. The overflow pipe  62 A has an elbow portion  65 A which defines an upper end portion  66 A and a lower end portion  67 A. It will be understood that the overflow pipe  62 A may be made of copper, plastic, or any other suitable material. 
     The upper end portion  66 A has threads  68 A on its outer surface and also has an outer end  70 A. The outer end  70 A defines an inlet  71 A to the upper end portion  66 A of the overflow pipe  62 A. The inlet  71 A is adapted to fit through the bathtub overflow port. 
     The overflow fitting  60 A also has a lip  74 A extending radially outwardly from an outer surface of the overflow pipe  62 A between the elbow portion  65 A and the upper end portion  66 A. The lip  74 A is spaced from the inlet  71 A to engage an outer surface of the bathtub end wall  24  around the bathtub overflow port  30 , thereby allowing only the upper end portion  66 A to pass through the overflow port  30 . 
     A thin diaphragm  80 A is sealed to the outer end  70 A of the end portion  66 A. The diaphragm  80 A is a circular membrane and has a diameter that is not less than the diameter of the outer end  70 A of the overflow pipe  62 A. In one embodiment, the diaphragm  80 A is integral with the outer end  70 A and is held to the outer end  70 A only through having been integrally formed therewith. The diaphragm  80 A may be hermetically sealed to the outer end  70 A. The diaphragm  80 A may be composed of plastic material, flexible rubber, or the like. The diaphragm  80 A is composed of a material that is easily punctured or easily removable. 
     The overflow fitting  60 A further includes a nut element  90 A having threads compatible with the threads  68 A on the upper end portion  66 A of the overflow pipe  62 A. The nut element  90 A removably secures the overflow pipe  62 A to the bathtub  20  by compressing the end wall  24  between the nut element  90 A and the lip  74 A. The nut element  90 A may be a slip nut. 
     As shown in  FIG. 9 , the nut element  90 A has a series of radially extending lugs  92 A along the nut element  90 A outer periphery. These lugs  92 A detachably engage the inner surface of a cap  96 A. The cap  96 A serves to cover the overflow fitting  60 A hardware. 
     During installation of the overflow fitting  60 A, a washer  94 A may be placed between the upper end portion  66 A of the overflow pipe  62 A and the nut element  90 A. The washer  94 A seals the overflow fitting  60 A to the tub  18 . 
     In operation, the drainage system comprising the ports  28  and  30 , and pipes  34 ,  36 , and  38  are installed as shown in  FIG. 2 . The vent pipe  40  and connecting pipe  42  are also installed. 
     In the conventional testing procedure, the port  28  is plugged in any convenient manner. The fitting  58  with diaphragm  64  is installed into drain pipe  34  as described above so there is no fluid access to the upper end of pipe  34  either inwardly or outwardly through overflow port  30 . The vent pipe  40  is charged with water at some elevation above connecting pipe  42  so that the building inspectors can check to see if there are any leaks in the system. Having determined that there are no leaks, the water is purged from the system. The plumber can then approach overflow port  30 , (because cap  78  is not yet installed) and by using knife  82  or the like, cuts can be made in diaphragm  64  leaving a cutout portion  84  as shown in  FIG. 5 . 
     Similarly, in operation the overflow fitting  60 A is attached to the second vertical drain pipe  34 A already plugged by the diaphragm  80 A as described above, so there is no fluid access to the upper end of second vertical drain pipe  34 A either inwardly or outwardly out of the overflow port  30 . The vertical vent pipe  40  is charged with water at some elevation above connecting pipe  42  so that it can be determined if there are any leaks in the system. 
     With reference to  FIG. 10 , having determined that there are no leaks, the water is purged from the system. The plumber can then approach overflow port  30 , and by using a cutting device  100 A, such as a knife of any other sharp object, cuts  82 A can be made in the diaphragm  80 A. This can be quickly and easily done without disassembling any of the structure of overflow fitting  60 A. Any valve linkage elements required may be installed through cuts  82 A, and any cap (such as cap  96 A shown in  FIG. 9 ) or cover for the overflow port  30  may be placed over the overflow pipe  62 A upper end portion  66 A. 
     Referring now to  FIGS. 11 and 12 , an alternate embodiment of the invention is shown wherein an overflow plate  110  is modified to slide vertically into position between the surface of the tub  112  and the retainer nut  114 . The overflow plate  110  has a first section, which comprises a rim  118  and a lip  120  extending inwardly therefrom, and a second section, which does not comprise a rim or a lip, thereby forming a recessed portion. The modified overflow plate  110  engages a notched surface  124  on at least a portion of the retainer nut  114  as shown in  FIG. 12 . The notch  124  may be incorporated along the entire circumference of the nut  114  as well. The overflow plate  110  according to this embodiment slides along an outward facing surface of the overflow plate  130  and engages the retainer nut  114  along the notched surface  124 . The notched surface  124  is located along a lateral face of the retainer nut  114 . The thickness of the lip  120  and the width of the notched surface  124  are such that the overflow plate  110  forms a near perfect fit once it engages the notched surface  124 , thereby firmly holding the overflow plate  110  in place between the retainer nut  114  and the surface of the tub  112 . 
     As shown in  FIG. 13 , the notched surface  124  of the retainer nut  114  may be located nearly concentrically about the thickness of the retainer nut  114 . According to this embodiment, the overflow plate  110  may be engaged with the centrally located notched surface  124  of the retainer nut  114 , by sliding the overflow plate  110  in a downward direction to engage the lip  120  of the overflow plate  110 . According to this embodiment, the overflow plate  110  is held in place by engaging both sides of the retainer nut  114  surrounding the notched surface  124 , thereby holding the overflow plate  110  firmly in place over the overflow port  130 . 
     Further alternative embodiments are shown in  FIGS. 14   a ,  14   b  and  15 , that show a removable seal  142  that may be selectively inserted or removed from the overflow assembly to prevent or permit water to flow through the overflow assembly  130 . The removable seal  142 , according to this embodiment, is such that it may be inserted into a slot  144  formed in the threaded portion  134  of the overflow assembly  130 , thereby sealing the overflow valve  130 , or removed from the slot  144 , thereby exposing the overflow port  130  without requiring a knife or other tool to cut out the seal  142  and potentially requiring the plumber to replace the seal  142  at a later time. 
     Referring now in detail to  FIGS. 14   a  and  14   b , according to one embodiment the seal  142  is inserted into a slot  144  formed within the threaded portion  134  of the overflow valve  130 , such that the seal  142  resides in a vertical plane within the threaded portion  134  of the overflow assembly  130 . The diameter seal  142  is substantially congruent with the diameter of the threaded portion  134  of the threaded portion  134  overflow valve  130 , as best shown in  FIG. 14   b . The seal  142  may have a pull ring  148 , which extends outside the slot  144  formed in the threaded portion  134  of the overflow assembly  130  so that the plumber may readily grasp the pull ring  148  and remove the seal  142  from the slot  144  in the threaded portion  134  of the overflow valve. 
     In yet another embodiment, the seal  142   b  is formed in a slot  144   b  that is formed in the retainer nut  150 , which may be modified to extend outwardly from the outer most surface of the threaded portion  134  overflow assembly  130 , as shown in  FIG. 15 . The seal  142   b  according to this embodiment operates in the same fashion is that described in relation between  FIGS. 14   a  and  14   b , in that the seal  142   b  may be removed or inserted at the discretion of the user. 
     It is therefore seen from the description above and accompanying drawing figures that this invention eliminates any need to seal the overflow pipe  34 ,  60 A even after the overflow pipe  60 A has been attached to the second vertical drain pipe  34 A. The invention also eliminates any need to remove sealing components from the overflow port  30  after the testing procedure has taken place. In addition, the invention allows a user to install an overflow fitting  58 ,  62 A without using solvent cement. This invention also facilitates the testing procedure and reduces the time needed to seal the overflow port  30 , and then to open the diaphragm  64 ,  80 A for possible fluid flow. 
     It is therefore seen this invention will achieve at least all of its stated objectives.