Patent Publication Number: US-9834920-B2

Title: Plastic floor drain

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     Embodiments relate to sinks or drains which treat water or waste liquid which include a strainer, are located on a floor with the strainer level with the floor, and with provisions for disposal of subsurface waste. 
     Current examples of plastic floor drains are inflexible in that they are configured in the process of manufacture, and cannot be adjusted to varying requirements existing at the site of installation in buildings during construction. Such inflexibility increases inventory costs and causes delays in building construction. 
     The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings. 
     Embodiments of the present disclosure provide plastic floor drains which are inexpensive and flexible and facilitate installation under varying conditions. Embodiments, through the use of common parts, reduce the costs and labor involved in providing a variety of floor drains to meet divergent requirements. 
     BRIEF SUMMARY OF THE INVENTION 
     The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tool and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above—described problems have been reduced or eliminated, while other embodiments are directed to other improvements. 
     Embodiments include plastic floor drain which comprises an approximately square receptor having an open top with a notch and a rim at the open top, an outlet at the bottom, and four sides. Each side has a shoulder located along the width of each side at approximately ⅓ the distance from the top to the bottom of the body. 
     Embodiments include a plastic floor drain which comprises an approximately square receptor having an open top with a notch and a rim at the open top, an outlet at the bottom, and four sides. Each side has a shoulder having a bottom side and located along the width of each side at approximately ⅓ the distance from the top to the bottom of the receptor. There are a multiplicity of seepage holes in the receptor arrayed along the top sides of the shoulders. A four-sided anchor flange is adhesively connected to the shoulder. A flashing clamp is attached by connectors to each side of the flashing clamp, each flashing clamp being capable of retaining a membrane between the anchor flange side and the flashing clamp. 
     In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment plastic floor drain  100 . 
         FIG. 2  is a cross-sectional view of a first embodiment plastic floor drain taken at line  2 - 2  of  FIG. 1 . 
         FIG. 3  is an exploded view of a first embodiment plastic floor drain. 
         FIG. 4  is a perspective view of a second embodiment plastic floor drain. 
         FIG. 5  is a cross-sectional view of a second embodiment plastic floor drain taken at line  5 - 5  of  FIG. 4 . 
         FIG. 6  is an exploded view of a second embodiment plastic floor drain. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of a first embodiment plastic floor drain  100 . Visible in  FIG. 1  is a square receptor  102  with four sides  104 . Each side  104  has a shoulder or ridge  108  located along the width of each side at approximately ⅓ the distance from the top to the bottom of the receptor. Also visible is a overlying grate  110  comprised of an overlying grate rim  112  and overlying grate mesh  114 . 
       FIG. 2  is a cross-sectional view of a first embodiment plastic floor drain taken at line  2 - 2  of  FIG. 1 . Visible in  FIG. 2  is a receptor  102 , receptor sides  104 , a shoulder  108  on each receptor side  104 , a notch at the top of each receptor side, and a rim  103  at the top of each receptor side. An open top  101  is at the top of the receptor  102 . Also visible in  FIG. 2  is an overlying grate  110  with an overlying grate rim  112  and a overlying grate mesh  114 . A square sediment tray strainer  116  with holes in the bottom (not shown in  FIG. 2 ) is located at the bottom of the receptor. A slip outlet  106  at the very bottom of the receptor is shown inserted into a drain pipe  140 . 
     The first embodiment plastic floor drain of  FIG. 2  is shown embedded in a concrete floor. Visible in  FIG. 2  is the structural concrete pour  142  and tiles  146  or other floor coverings on top of the structural concrete. 
       FIG. 3  is an exploded view of a first embodiment plastic floor drain. The elements shown in  FIG. 3  are the same as those shown in  FIG. 2 . 
       FIG. 4  is a perspective view of a second embodiment plastic floor drain. Visible in  FIG. 4  is the receptor  102 , one receptor side  104 , a hub outlet  107 , receptor rim  103 , a portion of the square flange  120  comprised of four rectangular flange arms  121 , two of which are visible in  FIG. 4 . Also visible are the four flashing clamps  122  and the bolts  124  which connect the flashing clamps  122  to the flashing arms  121 . Weep holes  134  are seen in the receptor sides  104 . Flange bold sockets  126  protrude below the flange arms  121 . 
     The embodiment of  FIG. 4  includes an inserting grate  128 , which is comprised of an inserting grate rim  130  and inserting grate mesh  132 . 
       FIG. 5  is a cross-sectional view of a second embodiment plastic floor drain taken at line  5 - 5  of  FIG. 4 . Elements  101 - 104  and  107 - 109  in the second embodiment are the same as those shown in  FIG. 2  as elements of the first embodiment. This second embodiment differs from the disclosed first embodiment primarily in the addition of the square flange  120  with four rectangular flange arms  121 . Flashing clamps  122  are capable of attachment to the flange arms  121  by flashing clamp bolts  124 . The flange  120  is attached to the shoulder or ridge  108  by an adhesive. This attachment may be done by the manufacturer or by the user in the field before the drain is installed. Also visible in  FIG. 5  are seep holes  134 . The seep holes may be made by the manufacturer or by the user by drilling through the receptor walls  104  at points indicated by markings on the flange arms  121 . 
     In  FIG. 5  the second embodiment plastic floor drain is shown installed in an above grade building floor. Visible in  FIG. 5  is the structural concrete pour  142 , an overlying water impervious membrane  148 , the secondary lightweight concrete pour  144  and the tile  146  finishing surface of the floor. The membrane  148  covers the structural concrete pour  142  with a square hole cut in it to accommodate the second embodiment plastic floor drain  105 . The edges of the membrane  148  are sealed by clamping between the flange arms  121  and the flashing clamps  122 . Any moisture which penetrates the finish tiles  146  and the secondary concrete pour  144  is conveyed by the membrane  148  through the weep holes  134  where it enters the drain pipe  140 . 
     In the second embodiment shown in  FIG. 5  an inserting grate  128  is shown with a inserting grate rim  130  which has an inserting grate rim ear  131  which rests on the notch  109  at the top of the receptor walls  104 . In the second embodiment the inserting grate  128  is interchangeable with the overlying grate ( 110  in  FIG. 2 ) of the first embodiment. Also visible in  FIG. 5  is the hub outlet  107  at the bottom of the receptor which fits on the outside of the drain pipe  140 . In the second embodiment the hub outlet  107  is interchangeable with the hub outlet ( 107  in  FIG. 2 ) of the first embodiment. Also, in the second embodiment the dome strainer  118  is interchangeable with the sediment tray strainer ( 116  in  FIG. 2 ) of the first embodiment. 
       FIG. 6  is an exploded view of a second embodiment plastic floor drain. The elements of  FIG. 6  are the same as those of  FIG. 5 . In addition,  FIG. 6  shows flashing clamp bolt holes  123  in the flashing clamps and in the arms  121  of the flange  120 . 
     The first embodiment plastic floor drains are typically installed in on grade applications, for example, in a basement, where there is only one concrete pour. This minimizes the expense of the plastic floor drains. The shoulder provides structural stability to the drain against forces directed to the top of the drain. 
     The second embodiment plastic floor drains are typically installed in above grade applications, above the lowest floor. The receptor is embedded in the structural concrete pour, typically four inches thick. A waterproof membrane is placed on the structural concrete slab. A secondary pour of concrete, generally lightweight concrete is placed on the membrane. Tiles or other finishing material completes the floor installation. The floor sink represents a penetration of the membrane as a portion of the membrane to accommodate the drain is removed. The penetration represented by the sink is sealed by clamping the membrane to the sink by using flashing clamps on all sides. The use of weep holes in the receptor above the installed flange allows water or other fluids which penetrate the finishing material and the secondary pour concrete to enter the drain and be removed rather than seeping to other floors. 
     In the second embodiment plastic floor drains the flange serves a second structural function. Forces on a floor drain are exerted from above, at the top of the drain. The flange provides structural stability against such forces and positively locks the drain in place in the floor. 
     Although only a single first and a single second embodiments are shown in the Figs., it should be noted that there a large number of possible embodiments are included in the category of first and second embodiments. 
     Although a dome strainer is shown with a first embodiment and a sediment tray with a second embodiment, it should be noted that any strainer may be used with any embodiment. Although a slip outlet is shown with a first embodiment and a hub outlet with second embodiment, it should be noted that any outlet may be used with any embodiment. Although an overlying grate is shown with a first embodiment and an inserting grate with a second embodiment, it should be noted that any grate may be used with any embodiment. 
     In embodiments the plastic floor drain receptors, flanges, flashing clamps grates and strainers are manufactured of any suitable hard, strong, resilient, impervious plastic. Suitable plastic polymers include polyvinyl chloride (PVC) and acrylonitrile butadiene styrene (ABS). In embodiments, the plastic floor drain can be used with fluids at temperatures from −13° F. to 200° F. In embodiments, the receptor rim is coated with nickel bronze. In embodiments, the grate is manufactured from acid resistant coated cast iron. 
     Any strong resilient water impervious material may be used as the membrane. In embodiments, the membrane is manufactured of plastic, rubber, lead, or tar paper. 
     Any suitable strong adhesive may be used to attach the flange to the receptor. Suitable adhesives include PVC solvents when PVC is the material of manufacture of the receptor and of the flange; and ABS solvents when ABS is the material of manufacture of the receptor and of the flange. In embodiments the adhesive used to attach the flange is the same adhesive used in other plumbing on the building, for example, in connecting pipes or connecting the plastic floor drain to the outlet pipe. This minimizes the expense in installing the plastic floor drain. 
     In embodiments, the receptor rim is 12 inches from side to side. In embodiments the height of the drain is 8¼ inches from the top of the grate rim to the bottom of the outlet. In embodiments, the flange is 14 inches from one side to the other. 
     The use of common parts, the receptors, strainers, grates and outlets, in the first and second embodiments has a number of advantages. It minimizes the inventory expense for the manufacturer, wholesalers, and users who install the drains in buildings. It provides flexibility to the user, whose requirements may change as buildings progresses. 
     While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope. The applicant or applicants have attempted to disclose all the embodiments of the invention that could be reasonably foreseen. There may be unforeseeable insubstantial modifications that remain as equivalents.