Patent Publication Number: US-11047126-B1

Title: Adjustable drain assembly and retrofit kit for adjustable drain assembly

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to floor drains generally and, more particularly, to floor drains having a leveling mechanism. 
     2. Description of Related Art 
     A floor drain is used to funnel liquids from a floor surface into a drain pipe. The floor drain typically has a grate or strainer attached to the top drain to allow liquid to flow through the drain, but prevent larger solid objects from entering the floor drain. A particular type of floor drain known as an adjustable floor drain, as shown in  FIGS. 1 and 2 , employs a strainer  10 , a head  20 , a membrane clamp collar  30 , and a lower body  40 . The head  20  has a long threaded shank  22  that allows the head  20  to be adjusted upwardly and downwardly via a mating thread  32  in the membrane clamp collar  30 . The head unit  20  is generally a one-piece component with the long threaded shank  22  extending upwardly and transitioning to a larger diameter flank portion  24  having a machined shoulder portion  26 . The machined shoulder portion  26  of the head  20  receives the strainer  10 , which is typically secured to the head  20  using machine screws. The clamp collar  30  is secured to the lower body  40  via machine screws  43 . The lower body  40  defines a passageway  44  therethrough for receiving a drain pipe  46 . 
     Referring to  FIG. 2 , a problem develops during the installation of these types of drains due to variances associated with the finished floor height and pitch. During installation, the lower body  40 , clamp collar  30 , and head  20  are positioned, supported, and leveled. The head  20  is screwed up or down to adjust to a desired height using the threaded shank  22  and mating thread  32 . Concrete  50  is poured to encase the entire assembly just below or up to the top level of the head  20  and a finished floor surface  55 , such as ceramic or quarry tile, is laid on the top of the concrete  50 . A problem can occur at this time if the head unit  20  of the drain assembly was incorrectly adjusted to compensate for the total thickness of the finished floor surface  55 , e.g., the tile and thin set mortar. If the top surface of the head  20  is too low, then the strainer  10  will not be flush with the finished floor surface  55 . Further, if the pitch of the concrete  50  and the finished floor surface  55  is not level with the top surface of the head  20 , the strainer  10  will not be level or flush with the finished floor surface  55 . 
     SUMMARY OF THE INVENTION 
     With parenthetical reference to the corresponding parts, portions or surfaces of the disclosed embodiment, merely for purposes of illustration and not by way of limitation, the present invention broadly provides in a first embodiment a structure positioned adjacent to a floor surface for connecting to a drain pipe ( 278 ). The structure includes a head ( 123 ) having an opening ( 124 ) leading to an inside surface ( 138 ) defining a passageway. The inside surface ( 138 ) has a tab ( 135 ) extending therefrom. The tab ( 135 ) is disposed below and in spaced apart relation to the opening ( 124 ). A leveling member ( 144 ) has a head ( 153 ) with slots ( 154 ) defined therein for turning the leveling member ( 144 ). The leveling member ( 144 ) is supported by the tab ( 135 ) and is configured and arranged to be displaceable in a first direction relative to the tab ( 135 ). A frame ( 175 ) has an upper surface and a lower surface. The frame ( 175 ) has a bracket ( 187 ) that is angled downward and inward from the lower surface. The bracket ( 187 ) has a distal portion configured and arranged to attach the frame ( 175 ) to the leveling member ( 144 ) at a position below the head ( 153 ) of the leveling member ( 144 ). 
     In another aspect of the invention, the leveling member ( 144 ) further comprises the head ( 153 ) having a first diameter, a shank ( 156 ) having a first portion ( 159 ) and a second portion ( 165 ). The second portion ( 165 ) has a diameter greater than the first portion ( 159 ) such that a groove ( 172 ) is formed between the second portion ( 165 ) and the head ( 153 ). 
     The groove ( 172 ) is configured and arranged to engage with the distal portion of the bracket ( 187 ) on the frame ( 175 ). 
     In another aspect, the structure further comprises a strainer ( 184 ) that is positioned adjacent the top surface of the frame ( 175 ). 
     In another aspect, the strainer ( 184 ) has an access opening ( 196 ) defined therein. At least a portion of the leveling member ( 144 ) is aligned with the access opening ( 196 ). 
     In another aspect, the frame ( 175 ) is substantially ring-shaped and further comprises a rim ( 181 ) surrounding the top surface. The rim ( 181 ) forms a shoulder for receiving the strainer ( 184 ). 
     In another aspect, the head ( 153 ) has a threaded shank ( 132 ) and a flange portion extending outwardly from the shank. 
     In another aspect, the structure further comprises a collar ( 260 ) having an internal surface having internal threads ( 262 ) configured and arranged to engage with the threaded shank ( 132 ) on the head ( 123 ). The head ( 153 ) threadingly engages with the collar ( 260 ) and is capable of displacement relative to the collar ( 260 ). 
     In another aspect the structure further comprises a lower body ( 270 ) configured and arranged to receive the collar ( 260 ). The lower body ( 270 ) defines a passageway therethrough. 
     In another aspect, the structure further comprises a drain pipe ( 278 ) secured to the lower body ( 270 ). 
     In another embodiment, a drain assembly ( 200 ) is provided with a head ( 123 ) having a threaded shank ( 132 ) and having an opening ( 124 ) leading to an inside surface ( 138 ) defining a passageway. The inside surface ( 138 ) has a tab ( 135 ) extending therefrom. The tab ( 135 ) is disposed below and in spaced apart relation to the opening ( 124 ). A leveling member ( 144 ) has a head ( 153 ) with slots ( 154 ) defined therein for turning the leveling member ( 144 ). The leveling member ( 144 ) is supported by the tab ( 135 ) and is configured and arranged to be displaceable in a first direction relative to the tab ( 135 ).
         A frame ( 175 ) has an upper surface and a lower surface. The frame ( 175 ) has a bracket ( 187 ) angled downward and inward from the lower surface. The bracket ( 187 ) has a distal portion configured and arranged to attach the frame ( 175 ) to the leveling member ( 144 ) at a position below the head ( 153 ) of the leveling member ( 144 ). A collar ( 260 ) having an internal surface having internal threads ( 262 ) is configured and arranged to engage with the threaded shank ( 132 ) on the head ( 123 ) such that the head ( 123 ) threadingly engages with the collar ( 160 ) and is capable of displacement relative to the collar ( 160 ). A lower body ( 270 ) is configured and arranged to receive the collar ( 260 ). The lower body ( 270 ) defines a passageway there through. A drain pipe ( 278 ) is secured to the lower body ( 270 ).       

     In another aspect, the leveling member ( 144 ) has a head ( 153 ) with a first diameter ( 168 ), and a shank ( 156 ) having a first portion ( 159 ) and a second portion ( 165 ). The second portion ( 165 ) has a diameter ( 168 ) greater than the diameter ( 162 ) of the first portion ( 159 ) such that a groove ( 172 ) is formed between the second portion ( 165 ) and the head ( 153 ). The groove ( 172 ) is configured and arranged to engage with the distal portion of the bracket ( 187 ) on the frame ( 175 ). 
     In another aspect, the drain assembly includes a strainer ( 184 ) positioned adjacent the top surface of the frame ( 175 ). 
     In another aspect, the strainer ( 184 ) has an access opening ( 196 ) defined therein. A portion of the leveling member ( 144 ) is aligned with the access opening ( 196 ). 
     In another aspect, the frame ( 175 ) is substantially ring-shaped and further comprises a rim ( 181 ) surrounding the top surface. The rim ( 181 ) forms a shoulder for receiving the strainer ( 184 ). 
     In another embodiment, a retrofit kit ( 300 ) is disclosed for use with a head ( 310 ) positioned adjacent to a floor surface for connecting to a drain pipe ( 478 ). The kit ( 300 ) includes a base ring ( 303 ) having an opening ( 304 ) defined therein. The base ring ( 303 ) is configured and arranged to attach to the head ( 310 ). The base ring ( 303 ) has an upper surface and a lower surface. A tab ( 335 ) is supported below the lower surface of the base ring ( 303 ). The tab ( 335 ) is disposed below and in spaced apart relation to the opening ( 304 ). A leveling member ( 344 ) having a head ( 353 ) with slots ( 354 ) defined therein for turning the leveling member ( 344 ). The leveling member ( 344 ) is supported by the tab ( 335 ) and is configured and arranged to be displaceable in a first direction relative to the tab ( 335 ). A frame ( 375 ) has an upper surface and a lower surface. The frame ( 375 ) has a bracket ( 387 ) angled downward and inward from the lower surface. The bracket ( 387 ) has a distal portion configured and arranged to attach the frame ( 375 ) to the leveling member ( 344 ) at a position below and spaced apart from the head ( 353 ) of the leveling member ( 344 ). 
     In another aspect, the leveling member ( 344 ) has a head ( 353 ) having a first diameter, and has a shank ( 359 ) having a first portion ( 359 ) and a second portion ( 365 ). The second portion ( 365 ) has a diameter greater than the first portion ( 359 ) such that a groove ( 372 ) is formed between the second portion ( 365 ) and the head ( 353 ). The groove ( 372 ) is configured and arranged to engage with the distal portion of the bracket ( 387 ) on the frame ( 375 ). 
     In another aspect, the drain assembly further comprises a strainer ( 384 ) positioned adjacent the top surface of the frame ( 375 ). 
     In another aspect, the kit includes a strainer ( 384 ) having an access opening ( 396 ) defined therein. At least a portion of the leveling member ( 344 ) is aligned with the access opening ( 396 ). 
     In another aspect, the kit includes a frame ( 375 ) that is substantially ring-shaped and further comprises a rim ( 381 ) surrounding the top surface, the rim ( 381 ) forming a shoulder for receiving the strainer ( 384 ). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of a prior art floor drain assembly; 
         FIG. 2  is a cross-sectional view of the prior art floor drain assembly of  FIG. 1 , showing the floor drain assembly in an installed position; 
         FIG. 3  is a perspective view of an adjustable floor drain assembly according to one embodiment of the present invention; 
         FIG. 4  is a front elevational view, partially in cross section, of the embodiment shown in  FIG. 3 ; 
         FIG. 5  is top plan view of the embodiment shown in  FIG. 3 ; 
         FIG. 6  is an exploded perspective view of the embodiment shown in  FIG. 3  with a cover; 
         FIG. 7  is a front elevational view, partially in cross section, of the embodiment shown in  FIG. 6 ; 
         FIG. 8  is an exploded cross-sectional view of the embodiment shown in  FIG. 3  being used in a drain system; 
         FIG. 9  is a perspective view of one embodiment of a retrofit kit according to the present invention; 
         FIG. 10  is a top plan view of the embodiment shown in  FIG. 9 ; 
         FIG. 11  is a front elevational view of the embodiment shown in  FIG. 9 ; and, 
         FIG. 12  is an exploded cross-sectional view of the embodiment shown in  FIG. 9  being used in a drain system. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, debris, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof, (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or of rotation, as appropriate. 
     According to one embodiment, shown generally in  FIGS. 3-7 , and initially referring to  FIG. 3 , an adjustable floor drain assembly  120  includes a head  123  having a flange  126  at a first end  129  of the head  123 . The head  123  has an opening  124  ( FIG. 4 ) leading to a passageway for draining fluids. The head  123  also includes a set of external threads  132 . A plurality of tabs  135  extend from an inside surface  138  of the head  123 . The tabs  135  may be provided with a threaded opening  141  that receives a leveling member  144  which may comprise a screw with threads. The leveling member  144  has a first portion  147  containing a set of external threads  150 . The leveling member  144  also includes a head  153  with slots  154  for a turning tool to fit into. Turning to  FIG. 4 , the leveling member  144  includes a shank  156  with a first portion  159  having a first diameter  162 . The shank  156  also includes a second portion  165  with a second diameter  168  that is greater than the first diameter  162 . The second diameter  168  may be approximately equal to the diameter  162  of the head  153 . The first portion  159  is disposed between the head  153  and the second portion  165 . The change in diameter between the head  153  and the second portion  165  along the length of the leveling screw  144  provides a groove  172 . 
     As best shown in  FIG. 5 , a frame  175  has a support surface  178  that is bordered by a rim  181 . The support surface  178  receives a strainer  184  (shown in  FIGS. 4 and 6 ). The strainer  184  may be circular with a plurality of openings and a plurality of flow passages defined therein. The flow passages permit the flow of fluid there through, but prevent the passage of solids of a particular size. 
     Returning to  FIG. 4 , an L-shaped bracket member  187  may extend from the bottom of the frame  175 . The L-shaped bracket member  187  has a distal portion  188  that engages with the leveling member  144  inside the groove  172 . As shown in  FIG. 3 , the distal portion  188  may include an opening  189  defined by a pair of opposed members  188 A and  188 B. Accordingly, each leveling member  144  is operatively associated with the frame  175  such that raising and lowering the leveling member  144  results in raising and lowering the portion of the frame  175  at or near the leveling member  144 . 
     As shown in  FIG. 5 , a set of fasteners  190  may be provided for attaching the strainer  184  to the frame  175 . 
     Turning to  FIGS. 6 and 7 , during installation and specifically the pouring of concrete, a cover  193  may be attached over the frame  175  at the top of the adjustable floor drain assembly  120 . The strainer  184  may be provided with a plurality of openings  196 . The openings  196  provide access for a turning tool to be inserted into the head  153  of the leveling member  144 . As a result, after the concrete is poured and the final floor surface is installed, the height and angle of the upper surface of the strainer  184  may be adjusted to be level or flush with the finished floor surface by adjusting the position of the frame  175  via the leveling members  144 . 
     Referring to  FIG. 8 , upon assembly of the floor drain system  200 , the threaded shank  132  of the head  123  is secured to a mating thread  262  of the collar  260  allowing for upward and downward adjustment of the head  123 . The collar  260  defines a passageway  264  therethrough and is secured to a flange portion  272  of the lower body  270  via screws  276 . The lower body  270  defines a passageway  274  therethrough for receiving a drain pipe  278 . The drain pipe  278  may be secured to the lower body  270  via a friction fit with chalking, e.g., oakum and lead, provided between the inside of the lower body  270  and the outside of the drain pipe  278 . Any other suitable arrangements for securing the drain pipe  278  to the lower body  270  may also be provided. 
     After the head  123  is secured to the collar  260  and the head  123  is adjusted to a sufficient height, concrete is poured to encase the floor drain system  200  just below or up to the top surface of the head unit  123  and a finished floor surface, such as ceramic or quarry tile, is laid on the top of the cured concrete. 
     In certain installations of the floor drain system  200 , the concrete and finished floor surface are not level with the top surface of the frame  175  such that the strainer  184  will not be flush with the finished floor surface. In order to adjust the pitch of the frame  175  and strainer  184 , a turning tool is inserted through opening  196  and the turning tool is engaged with the slots  154  in the head  153  of the leveling member  144  to raise and lower the leveling member. The raising and lowering of the leveling member  144  provides for adjusting the height and slope of the strainer  84 . 
     Turning to  FIGS. 9-12 , a retrofit kit  300  for an adjustable drain assembly provides a base ring  303  that may be attached to a preexisting head  310  (shown in  FIG. 12 ) by fasteners  306 . The base ring  303  includes a tab portion  335  that is supported from a bottom surface  315  of the base ring  303  as shown in  FIG. 11 . A frame  375  may be adjusted by means of engagement between leveling members  344  with tab portions  335  on the base ring  303 . 
     Once the leveling members  344 , which carry the frame  375 , are engaged with the threaded surfaces inside the tab portions  335 , the height and angle of the upper surface of the strainer  384  can be adjusted by inserting a turning tool through openings  396  in the strainer  384 . The turning tool (not shown) is inserted through opening  396  and is engaged with slots  354  in the head  353  in order to turn the leveling screw  344 . Raising and lowering an individual leveling member  344  adjusts the height and angle of the portion of the strainer  384  near the leveling member  344 . The strainer  384  may be attached to the frame by means of fasteners  390 . The strainer  384  fits inside the frame  375  and is supported by a support surface  378  bordered by a rim  381 . The top of the strainer  384  may be flush with the top of the rim  381 . 
     Turning to  FIG. 11 , the tab portion  335  on the base ring  303  may be formed by an elongate member  318  having a first portion  321  angled downward and inward and a horizontal portion  322  having an opening  324  bordered by a threaded inner wall  327 . The base ring  303  is attached to the preexisting head  310  by fasteners  306 . 
     As shown the leveling members  344  may be formed in the same manner as described above in connection with leveling members  44 . The frame  375  may engage with a groove  372  formed in the leveling members  344 . The frame  375  may be provided with an L-shaped bracket member  387  having a distal portion configured to attach around the first portion  359  of the shank  356  in the groove  372 . The frame  375  has a support surface  378  bordered by a rim  381 . The strainer  384  may be attached to the frame  375  by means of fasteners  390 . 
     In  FIG. 12 , upon assembly of the retrofit kit  300  as part of a drain system  500 , a threaded shank  400  on the head  310  secures the head  310  to a mating thread  462  of the collar  460  allowing for upward and downward adjustment of the head  310 . The collar  460  defines a passageway  464  therethrough and is secured to a flange portion  472  of the lower body  470  via screws  476 . The lower body  470  defines a passageway  474  therethrough for receiving a drain pipe  478 . The drain pipe  478  may be secured to the lower body  470  via a friction fit with chalking, e.g., oakum and lead, provided between the inside of the lower body  470  and the outside of the drain pipe  478 . Any other suitable arrangements for securing the drain pipe  478  to the lower body  470  may also be provided. 
     After the head  310  is secured to the collar  460  and the head  310  is adjusted to a sufficient height, concrete is poured to encase the floor drain system  500  just below or up to the top surface of the head unit  310  and a finished floor surface, such as ceramic or quarry tile, is laid on the top of the cured concrete. 
     In certain installations of the floor drain, the concrete and finished floor surface are not level with the top surface of the frame  375  such that the strainer  384  will not be flush with the finished floor surface. In order to adjust the pitch of the frame  375  and strainer  384 , a turning tool is inserted through opening  396  and the turning tool is engaged with the slots  354  in the head  353  of the leveling member  344  to raise and lower the leveling member  344 . The raising and lowering of the leveling member  344  provides for adjusting the height and slope of the strainer  384 . 
     While certain embodiments of the adjustable floor drain assembly and retrofit kit for a floor drain assembly were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.