Patent Publication Number: US-2023146089-A1

Title: Lift rod pop-up drain assembly

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Application Ser. No. 63/223,357 filed on Jul. 19, 2021, which is incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to the field including sink drains with plugs and plug control assemblies. 
     BACKGROUND OF THE INVENTION 
     Currently, bathroom sinks are provided with a pup up drain plug which is operated by a lift rod rotatably connected to a horizontal pivot rod which is also rotatably connected to the drain body whereby a spherical ball is integral to the horizontal pivot rod and is rotatably captured within the drain body. The sphere is rotatably captured by a threaded retaining nut which is hand threaded and tightened over the sphere and onto the drain body to provide a fulcrum point for the lift rod which is connected at the opposite end from the lift rod, to the bottom of the drain plug and acts as a lever to raise or lower the drain plug. Attaching the horizontal lever in this way is quite effective in that the retaining nut can be hand tightened to provide a leak proof connection and the lift rod can be easily raised or lowered to operate the drain plug. However, the act of assembling these parts is cumbersome and time consuming. Further, aligning the end of the horizontal pivot rod with the hole in the bottom end of the drain plug is sometimes difficult. The connecting and disconnecting of the aforementioned parts is done on initial installation, whenever the drain or pipes are clogged, whenever something is lost down the drain, or when a time might come to replace the drain. In any of these events, an improved system to allow for faster and easier assembly is needed. 
     DESCRIPTION OF THE RELATED ART 
     The closest related art appears to be China Patent No. CN105757374B which was published on Sep. 14, 2016 and teaches a drain with a pop-up drain plug including a quick attach assembly rotatably connecting the pop-up lever to the drain body which is incorporated by reference herein. China Patent 105736871 which was published on Apr. 20, 2018 teaches a sink plunger lift rod assembly. China Patent 105757374B was published on Jul. 13, 2016 and teaches a ball and valve assembly for a sink having a socket ball locking means. 
     Conventional pop-up drain assemblies typically use a threaded retaining nut which threadably engages a threaded tee stem projecting from the drain conduit body. The retaining nut adjustably holds and compresses a ball extending near a distal end of the pivot rod which is raised and lowered with a lift rod having a top portion connecting to a pull via a clevis and which extends above a sink. The lift rod is usually connected to the pivot rod by sliding the pivot rod through a selected hole in the lift rod whereby the pivot rod is secured in position by a spring clip. 
     Plumbers spend considerable time assembling the apparatus for each sink. Moreover, the distal end of the pivot rod is disposed through the connector tee stem and is positioned within the pop-up assembly conduit for engaging the drain plunger. The use of a threaded retaining nut and spring clips lack precision and require adjustment during installation. 
     There is a need for a quick installation device with insures proper placement with guides and stops for proper alignment and spacing and can be retained with a quick  180  degree turn of a retaining wing nut. 
     SUMMARY OF THE INVENTION 
     The invention describes a quick install lift rod pop-up sink drain assembly comprising a drain body, a drain plug, a horizontal pivot rod used as a lever for raising and lowering the drain plug, a lock ring which rotatably secures the horizontal pivot rod to the drain body, and a lift rod rotatably connected to the outer free end of the horizontal pivot rod and used to raise or lower the free end of the horizontal pivot rod. A spherical portion of the horizontal pivot rod is rotatably captured inside a free end of a connector which is integral with the drain body and which contains pawls which capture the spherical portion of the rod and allow up and down movement of the rod with respect to the drain body, causing the drain plug to open and close. In addition, stops and guides are used to quickly align the lift rod and pivot rod and for insertion of the ball in the correct position quickly and accurately. 
     In accordance with the present invention, there is provided a pop-up drain assembly comprising or consisting of a drain body, a drain plug, a horizontal pivot rod, a lock ring, and a lift rod rotatably connected to the outer free end of the horizontal pivot rod; the drain body being mostly cylindrical and comprising a lower unthreaded section, an upper threaded section and a middle unthreaded section with a connector drain tee stem extending outward perpendicularly from the middle section. The drain tee stem includes a smooth section terminated by a castellated section containing at least two pawls, each of the pawls including a radially outward protruding step and an inward facing ramped step. The horizontal pivot rod includes an integral spherical ball located about two inches from the first end. The drain plug has an aperture formed at the bottom end. The drain plug is inserted downward into the drain body. The aperture in the drain plug end is aligned with the drain tee connector stem. The first end of the horizontal pivot rod is pushed through the castellated section of the drain tee connector stem. The ball of the horizontal pivot rod is pushed through the pawls and snapped into the drain tee connector stem. The drain tee connector stem has an inner square annular void formed therein. The annular void is capable of receiving a flat ring seal, the curvature of the inward facing ramped steps matches the curvature of the ball. The drain tee connector stem has inner vertical guide walls and the horizontal pivot rod has square vertical shoulders cooperatively and slidably engaging the vertical guide walls. The lock ring comprises a hollow cylinder with two wings extending radially outward from outer walls of the lock ring and two downward extending lugs integral to bases of the two wings. The lugs cooperatively press against the drain body when the lock ring is tightened. The lock ring has an inner diameter equal to the outer diameter of a circle formed by the outer walls of the at least two pawls. The lock ring has a cylindrical void formed in the outer end for receiving the pawl steps extending radially outward from the free edges of the at least two pawls. The drain body has two stop lugs extending radially outward therefrom providing a positive stop to locate the lock ring in a position which causes the pawls to apply holding pressure against the ball. The drain plug comprises a cap, a longitudinal body with four longitudinal walls, which are perpendicular to one another, and a downward extending drain plug lug having an aperture in the bottom end. The first end of the horizontal pivot rod is inserted into the drain tee connector stem and then inserted into the aperture of the plug lug. The four longitudinal perpendicular walls together form a ‘X’ or a cross. The drain body has an integral arcuate lug extending radially inward and cooperatively engaging the cross, providing a guide to help insure that the drain plug is positioned properly in the drain body. 
     It is an object of this invention to provide a quick install lift rod type pop-up sink drain with a pop-up drain plug which can be assembled faster than the pop-up drain plug assemblies commonly used in the art. 
     It is an object of this invention to provide a sink drain with a pop-up drain plug which provides easy alignment of the hole at the bottom end of the plug with the end of the horizontal pivot rod which operates the plug, that alignment being provided by an arcuate plug alignment lug extending inwardly from an inside wall of the drain body. 
     It is an object of this invention to provide a sink drain with a pop-up drain plug which allows the spherical ball integral with the horizontal pivot rod to be rotatably snapped into a receiver which is integral with the body of the drain. 
     It is an object of this invention to provide a sink drain with a pop-up drain plug including a manual locking ring which causes the receiver to hold fast to the spherical ball. 
     It is an object of this invention to provide a sink drain with a pop-up drain plug including a flat ring held between the drain body and the spherical ball and wherein the inner edge contacting the ball is cambered, thus providing an enlarged sealing surface to provide a leak-proof connection. 
     It is an object of this invention to provide a sink drain with a pop-up drain plug wherein the drain body includes at least one outward extending lug which acts as a positive stop and a mark for registering the manual locking ring with the drain body in the position that provides for maximum locking force between the receiver and the spherical ball. 
     It is an object of the present invention to provide a smooth ball surface to smother operating movements and for rotation  90  degrees using an enlarge metal insert to improve the strength of the ball rod minimizing flexing of the ball rod associated with conventional ball rods consisting of plastic. 
     It is an object of the present invention to provide improved O-ring design to the bowl type seal washer to provide better sealing capability and reduce the compression of the rubber sealer. 
     It is an object of the present invention to provide two spaced apart rotation stoppers. 
     It is an object of the present invention to provide ball rod installation optimization whereby the rotary rod direction guide design makes the ball rod go into the pop-up body easily with minimal alignment. 
     It is an object of the present invention to provide a secured restrictor which aids in alignment. 
     It is an object of the present invention to utilize a bowl type seal washer to provide better sealing capacity and reduce the compression of the rubber seal. 
     Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the views wherein: 
         FIG.  1    is a perspective view of a pop-up drain assembly including the drain body with the drain plug, the horizontal pivot rod and the lift rod for a lift rod pop-up assembly; 
         FIG.  2    is a perspective view of the improved pop-up drain assembly of the present invention including the drain body with the drain plug, the horizontal pivot rod and the lift rod for a lift rod pop-up assembly; 
         FIG.  3    is a front right perspective view of the drain body; 
         FIG.  4    is the front perspective view of the manual lock ring; 
         FIG.  5    is a front view of the drain body with the horizontal pivot rod about to be inserted into the receiver; 
         FIG.  6    is a front view of the drain body with the horizontal pivot rod ball inserted into the receiver and the manual locking ring in the locked position; 
         FIG.  7    is an expanded cross-sectional view showing a conventional prior art drain tee connector stem having a round O-ring seated in an inner square annular forming a seal between the ball and the inner surface of the drain tee connector stem; 
         FIG.  8    is an expanded cross-sectional view of the present invention showing a drain tee connector stem having a resilient bowl type washer having a wedge shaped edge seated in an inner square annular forming a seal between the ball and the inner surface of the drain tee connector stem; 
         FIG.  9 A  is a perspective view of a pop-up assembly including the drain body the horizontal pivot rod and the lift rod and lock ring; 
         FIG.  9 B  is a perspective view of a pop-up assembly including the drain body the horizontal pivot rod and the lift rod and lock ring showing rotation of the pivot rod; 
         FIG.  9 C  is a perspective view of a pop-up assembly including the drain body the horizontal pivot rod and the lift rod and lock ring showing rotation of the pivot rod; 
         FIG.  10    is a right side view showing a conventional prior art receiver having an O-ring compressed between with the spherical ball inserted and the manual locking ring in the installed position and shows the stem requiring alignment extending into the ball receiving conduit; 
         FIG.  11    is a right side view of  FIG.  8    showing a drain tee connector stem receiver having a resilient bowl type washer compressed and wedged between the spherical ball and the manual locking ring in the installed position and showing the stem extending into the ball receiving conduit between alignment members wherein the wedge shaped washer reduces pressure and provides smoother ball surface rotation operation; 
         FIG.  12    is a side view of the receiver with the spherical ball inserted and the manual locking ring in the installed position of the receiver; 
         FIG.  13    is a right side view of the present drain body with the horizontal lever installed and the manual locking ring in position against two lugs extending outward from the drain body. 
         FIG.  14    is a cross-sectional view of the receiver area of the drain body and horizontal pivot rod taken vertically along the axis of the horizontal pivot rod of the conventional prior art device showing a void between the stem and receiver conduit requiring alignment of the stem; 
         FIG.  15    is a cross-sectional view of the present invention receiver area of the drain body and horizontal pivot rod taken vertically along the axis of the horizontal pivot rod showing stem guide disposed in the receiver conduit for quick and accurate self alignment of the stem and ball; 
         FIG.  16    is a side view of the pivot rod; 
         FIG.  17    shows a prior art pivot rod; 
         FIG.  18    is a top view of the horizontal pivot rod of the present invention having an inner metallic strengthening rod having a stepped down inner stem portion for cooperatively engaging alignment members within the stem receiving conduit and a proximate portion extending from the ball having a flared portion for a snug fit with the receiving conduit and larger lip for biasing against the locking ring; 
         FIG.  19    is a right perspective end view of the horizontal pivot rod of  FIG.  18    showing a thicker rod having a metal center and axial notches forming a corrugated body for improved lateral strength and rigidity; 
         FIG.  20    is a top through-hole view through the drain body of a conventional prior art drain assembly showing the secured restrictor supporting the rod on an axial rim hole; 
         FIG.  21    is a top through-hole view of the drain body of the instant invention showing the arcuate plug alignment lug in the axial bore for aligning the distal end of the pivot rod; 
         FIG.  22    is a perspective view of a drain stopper without the arcuate plug alignment lug; 
       and 
         FIG.  23    is a side view of the drain plug assembly showing the bottom of the drain plug extending downward therein for cooperative engagement with the stem and showing the vertical inner rod guides. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In accordance with the present invention, there is provided a sink pop-up drain assembly generally used for a bathroom sink, comprising a drain body, a drain plug, a horizontal pivot rod used as a lever for raising and lowering the drain plug, a lock ring which rotatably secures the horizontal pivot rod to the drain body, and a lift rod rotatably connected to the outer free end of the horizontal pivot rod and used to raise or lower the free end of the horizontal pivot rod. A spherical portion of the horizontal pivot rod is rotatably captured inside a free end of a connector which is integral with the drain body and which contains pawls which capture the spherical portion of the rod and allow up and down movement of the rod with respect to the drain body, causing the drain plug to open and close. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated  90  degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words “herein,” “above,” “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. When the claims use the word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list. 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     In accordance with the present invention, there is provided a pop-up drain assembly  10 , generally used for a bathroom sink, comprising a drain body  61 , a drain plug  62 , a horizontal pivot rod  1  used as a lever for raising and lowering the drain plug  62 , a lock ring  3  which rotatably secures the horizontal pivot rod to the drain body, and a lift rod  64  having a lift rod stem  9  removably held in position by a rotational lock mechanism  11 , rotatably connected to the outer free end of the horizontal pivot rod  1  and used to raise or lower the free end of the horizontal pivot rod  1 . 
     As shown in the  FIGS.  1 - 24   , the mostly cylindrical drain conduit body  61  includes a lower unthreaded section  610 , an upper threaded section  611  and a middle unthreaded section  22  with an integral drain tee connector stem  21  extending outward perpendicularly from the middle section  22  such that the drain tee connector stem  21  forms a ‘T’ connection with the drain body  61  wherein the tee connector stem  21  is fluidly connected with the drain body  61 . The drain tee connector stem  21  includes a smooth section terminated by a castellated section containing at least two pawls  211 . Each pawl  211  terminates with an outward protruding step  2112  and an inward facing ramped step  2111 . 
     The horizontal pivot rod  1  includes an integral spherical ball  11  located about two inches from the left end. The drain plug  62  in  FIG.  22    has an aperture  622  at the bottom end. With the drain plug inserted downward into the drain body  61 , the aperture  622  is aligned with the drain tee connector stem  21 . With reference to  FIG.  5   , the left end of the horizontal pivot rod  1  is pushed through the castellated section of the drain tee connector stem  21 . The ball  11  of the horizontal pivot rod  1  is pushed through the pawls  211  and snaps past the inward facing ramped steps  2111  of the pawls  211  and into the drain tee connector stem  21 . 
     In a conventional pop-up assembly, the drain tee connector stem  21  includes an inner square annular void into which is place a rubber or otherwise resilient O-ring  2113  forming a seal between the ball  11  and the inner surface of the shoulders of the stem receiving conduit for the drain tee connector stem  21 . The present invention replaces the round O-ring  2113  with a bowl type of rubber seal composed of rubber, silicone, or other suitable polymer or elastomer for forming a water tight seal or other resilient material and optionally flairs the shoulder for cooperative engagement of the bowl type of seal. The bowl type seal  2114  requires less compression pressure for a solid sealing fit and rotates more smoothly than a conventional O-ring. 
     The drain tee connector stem  21  includes an inner square annular void forming a square ramp or shoulder  2115  into which is place a rubber or otherwise resilient bowl type washer  2114  forming a seal between the ball  11  and the inner surface of the drain tee connector stem  21 . The curvature of the inward facing ramped step or shoulder  2114  as illustrated in  FIGS.  11  and  15    corresponds to the curvature of the ball  11  and thus, the ball  11  is tightly held with the drain tee connector stem  21  by the pressure of the inward facing ramped steps  2114  of the pawls  211  against the ball  11 . The resilient ring can be an O-ring is shown in the conventional prior art  FIGS.  10  and  14   , which utilizes a flat shoulder  2113  with the inner edge that contacts the ball  11  providing a smaller sealing surface as compared with the bowl shaped seal  2114  as shown best in  FIGS.  11  and  15   . The conventional O-ring  2113  is best shown in  FIGS.  10  and  14   . 
     Furthermore, as shown in  FIGS.  10  and  14   , the receiver area of the drain body and horizontal pivot rod taken vertically along the axis of the horizontal pivot rod of the conventional prior art device showing a void between the stem and receiver conduit with no alignment of the stem. The instant invention as shown in  FIGS.  11  and  15   , the receiver area of the drain body and horizontal pivot rod extends along the axis of the horizontal pivot rod showing stem guide disposed in the receiver conduit for quick and accurate self alignment of the stem and ball. 
     Thus the drain tee connector stem  21  provides a pivot point for the horizontal pivot rod  1  as the right end of the rod is raised or lowered. The free end of the rod  1  should only be able to move up and down and not left or right, as a spherical ball would allow. Therefore, vertical guide walls  2120  and  2121  are parallel with one another and aligned coaxially with and integral with the drain tee connector stem  21 . Vertical shoulders  110  of the rod  1  slide up and down inside the guide walls  2120  and  2121  as the free end of rod  1  is lowered and raised and, thus, left and right movement of the free end of horizontal pivot rod  1  is prevented as shown in  FIG.  23   . 
     As illustrated in  FIG.  4   , the lock ring  3  comprises a hollow cylinder  33  with preferably two wings  5 , similar to the wings on a wing retaining nut providing for manual turning of the lock ring  3  by pressing the thumb against one wing and the index finger against the other wing. The cylindrical portion of the lock ring  3  coaxially slides over the drain tee connector stem  21  and can be spun around the drain tee connector stem  21 . The lock ring  3  also includes two downward extending lugs  4  connected at the bases of the two wings  5 . The lugs  4  cooperatively press against the middle section  22  of the drain body  61  when the lock ring  3  is spun around the drain tee connector stem  21 , thus urging the lock ring  3  radially away from the drain body conduit section  22 . The cylinder  33  has an inner diameter equal to the outer diameter of a circle formed by the outer walls of the at least two pawls  211 . The cylinder  33  includes a cylindrical void  36  which receives the pawl steps  2112  extending radially outwards from the free edges of the at least  2  pawls  211 . As the lock ring  3  is turned or spun on the outside of the drain tee connector stem  21 , the lugs  4  encounter the outside of the drain body  61 , the lock ring is urged away from the drain body  61  and the inner walls of the lock ring squeeze the pawls  211  radially inward tightly against the ball  11 . This prevents the ball  11  from escaping out of the drain tee connector stem  21 . Further, the pawl steps  2112  are engaged against the outer walls formed by the cylindrical void  36 , which limits the lock ring movement and prevents the lock ring  3  from sliding off of the drain tee connector stem  21 . Stop lugs  8  which are integral with the drain body  61  provide a positive stop for locating the lock ring  3  in a position which causes the pawls  211  to apply holding pressure against the ball  11 . 
       FIG.  20    shows a conventional prior art through-hole view of the drain body inner side wall of the instant invention showing the axial bore for aligning the distal end of the pivot rod. 
       FIG.  21    shows a conventional prior art through-hole view of the drain body of the instant invention showing the arcuate plug alignment lug  2120  formed in the axial bore of the inner side wall  2019  for aligning the distal end of the pivot rod for engaging the distal tip  2030  of the lift rod. 
     The drain plug  62  comprises a cap  621 , a longitudinal body four longitudinal perpendicular walls  623 ,  624 ,  625  and  626 , and a downward extending drain plug lug  622  having an aperture formed therein. The end of the horizontal pivot rod  1  which is inserted into the drain tee connector stem  21  is also inserted in the aperture of the plug lug  622 . This allows the rod  1  to move the drain plug  62  up and down as the free end of the rod  1  is lowered or raised. The walls  623 ,  624 ,  625  and  626  together form a ‘+’ sign or cross when viewed from either the top or the bottom of the plug. 
     The drain plug  62 , without the cap  621 , could be inserted into the drain body  61  at the time of assembly at any angle such that the end of the rod  1  may not be aligned with the aperture in the bottom end of the drain plug. The present invention includes an improved integral arcuate lug  7  extending radially inward, providing a guide to help insure that the drain plug is positioned properly in the drain body  61 . 
     The pop-up drain assembly of the present invention is functionally similar to conventional bathroom sink drains; however, the assembly provided allows quick and easy installation as well as disassembly during normal maintenance tasks. Removal of the drain plug  62  is as simple as turning the lock ring  3  to  90  degrees and sliding the lock ring toward the drain body  61 , pulling the horizontal pivot rod out and then pulling the drain plug up and out. Reassembly is just the reverse. Proper placement of the horizontal pivot rod and the drain plug is provided by the arcuate lug  7  and the guide walls  2120  and  2121 , respectively. 
     The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplification presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims.