Patent Abstract:
A debris trap for a floor drain includes a rim defining an outer diameter, an inner diameter, a center, and a rim portion extending upwardly from an upper surface portion of the rim at or near the outer diameter. Prongs are integrally formed with the rim and spaced along at least part of the inner diameter. Each prong has a proximal portion extending radially inward from the rim, a free distal end that is only upwardly curved from the proximal portion toward the center, and a width that varies along a length of the prong.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of, and claims the benefit of, and priority to, U.S. patent application Ser. No. 12/862,689, filed on Aug. 24, 2010, and entitled “DEBRIS TRAP FOR A DRAIN,” the disclosure of which is hereby incorporated herein in its entirety by this reference. 
    
    
     BACKGROUND 
     Field of the Invention 
     The present disclosure relates generally to drains, such as for tiled showers and the like. More particularly, the present disclosure relates to a removable debris trap for a drain. 
     Related Art 
     There are a variety of styles and types of floor drains for showers and the like. Both round and square or rectangular drains are available, and there are a variety of mechanisms for connecting drain structures with associated drainage pipes. There are also a variety of materials and finishes that have been used for drains and drain grates. For many years, floor drains and grates have been made of non-corrosive metals, such as brass and stainless steel. More recently, because of their low cost and ease of use, polymer materials have been used for drain structures and drain grates, often in combination with metal structures. For example, drains comprising a polymer drain body and a metal drain grate are quite common. Drain grates comprising a polymer structure with a sheet metal cladding are also available. 
     One challenge with floor drains and other drains is the potential for clogs of hair and other debris. To prevent clogs of hair and other debris, hair traps and debris traps have been developed for drains. There are a variety of designs and configurations for hair and debris traps. However, with many of these, removal can be difficult and time-consuming, and cleaning can be a difficult and disgusting task. Additionally, some hair trap devices present an aesthetically undesirable appearance in or near a drain. 
     SUMMARY 
     It has been recognized that it would be advantageous to develop a debris trap for a drain that is effective at trapping hair and the like. 
     It has also been recognized that it would be advantageous to develop a debris trap for a drain that is easy to remove, clean, and replace. 
     In accordance with one embodiment thereof, the present invention provides a debris trap for a drain. The debris trap includes an annular rim, defining a center, with a plurality of radial prongs, extending from the rim toward the center, and oriented to catch debris in the drainage pathway. The debris trap is removably disposable within a drainage pathway of a drain body, below a removable drain grate of the drain. 
     In accordance with another aspect thereof, the invention provides a drain system, including a drain body and a debris trap. The drain body includes a circular lower portion defining an outlet, which is configured to mate with an underdrain structure, and an upper portion defining an inlet, configured to receive a drain grate in a frictional fit. The drain body also includes a circular recess below the upper portion and concentric with the outlet, having a diameter larger than an inner diameter of the outlet. The debris trap is configured to be disposed in the circular recess, and includes an annular rim defining a center, and a plurality of radial prongs extending from the rim toward the center, oriented to catch debris in the drainage pathway. 
     In accordance with yet another aspect thereof, the invention provides a method for removing debris from a drain. The method includes the steps of removing a drain grate from a drain body of the drain, removing a debris trap from a resting position within a drainage pathway of the drain body and below a level of the drain grate, removing debris from the debris trap, replacing the debris trap within the drain body, and replacing the grate. The debris trap includes an annular rim defining a center and a plurality of radial prongs extending from the rim to a free distal end a distance from the center, and removing debris from the debris trap comprises removing debris from the prongs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention, and wherein: 
         FIG. 1  is a perspective view of one embodiment of a floor drain body with a drain grate in place; 
         FIG. 2  is a perspective view of the drain grate of  FIG. 1  with the grate removed, showing a central recess above the outlet within the drain body; 
         FIG. 3  is a perspective view like that of  FIG. 2 , showing one embodiment of a removable debris trap disposed in the recess within the drain body; 
         FIG. 4  is a perspective view of an embodiment of a debris trap in accordance with the present disclosure; 
         FIG 5  is a side view of the debris trap of  FIG. 4 ; 
         FIG. 6  is a top view of the debris trap of  FIG. 4 ; 
         FIG. 7  is a close-up, perspective, partially sectional view of the debris trap of  FIG. 4 ; 
         FIG. 8  is a perspective view of another embodiment of a debris trap in accordance with the present disclosure; 
         FIG. 9  is a side, cross-sectional view of the debris trap of  FIG. 8 ; and 
         FIG. 10  is a close-up, perspective, partially sectional view of the debris trap of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. it will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention. 
     Shown in  FIG. 1  is a drain body or riser  10  with a grate  12  having drain openings  13 . The drain body is shown with the grate removed in  FIG. 2 . This drain body  10  is a one-piece unit, having a generally rectangular upper portion  14  defining an inlet, and a circular lower portion  16  defining an outlet and being configured to mate with an underdrain structure. It is to be understood that, while the drain body shown in  FIGS. 1 and 2  has a rectangular inlet, drain bodies having inlets of other shapes, such as circular, can also be used. The lower portion of the drain body includes external helical threads  18  for connection to the underdrain, allowing the height of the drain inlet to be adjusted by rotating the drain body. The drain body can be of an injection-molded polymer, such as ABS (Acrylonitrile Butadiene Styrene) plastic, allowing it to be strong and lightweight. 
     The inlet portion  14  of the drain body  10  includes a shoulder  20  on its inner perimeter, for supporting the drain grate  12 . Surrounding the shoulder is a grout rim  22  that is integral with the drain body. The grate  12  is supported only around it&#39;s perimeter by a narrow shelf (i.e. shoulder  20 ) in the drain body  10 . Just inside and below that shelf is a near-vertical surface  21  that extends down to the floor of the bowl  30 . Against this surface an inner perimeter rib or wall of the grate frame can make a light friction fit. The inner surface of the grout rim includes 90 degree filleted corners  26 . This configuration helps reduce binding of the grate and allows for a wide selection of grate opening configurations. The drain body can also include a step or recess  28  in the bawl floor  30 , which can allow for the inclusion of a debris trap device  50  (shown in  FIG. 3 ). 
     By design, the bowl  30  of the drain body  10  is relatively deep (compared to the size of the grate openings  13 ). This helps create a shadow and a blacked-out effect that is very desirable, especially where the drain body is black or some other dark color. When viewed from the top through the openings  13  in the grate  12 , the visibility of any build-up of soap scum, scale and hair will be substantially reduced. The grate looks clean and beautiful and is not detracted by a view of scum build up just below the surface. 
     The grout rim  22  provides a sharp termination at the top edge of the drain body  10 , and becomes substantially hidden to the eye when embedded into an adjacent grout line. When a drain grate  12  is inserted into the inlet portion  14  and supported by the shoulder  20 , friction between the Vertical surface  21  and a perimeter rib (not shown) of the drain grates frame holds the grate in place. A small clearance can be maintained between the grate  12  and the grout rim  22  to allow for drainage immediately around the slightly elevated grate. 
     Around the outer sides  34  of the inlet portion  14  of this embodiment of the drain body  10  are undercut grout locking features that help anchor the drain body with surrounding mortar and grout material. The undercut grout locking features can include a horizontal undercut edge  42 , and tapered or dovetail surfaces associated with vertical buttresses  36 , to cause the buttresses to interlock with surrounding grout, allowing the grout to capture the drain body and hold it in position in a dovetail arrangement. The buttresses have a dovetail shape that becomes wider as the buttress extends away from the sidewall  34  of the drain body. This provides dovetail surfaces that are angled toward the drain body, so that a mechanical interlock is created with grout material that surrounds the drain body. Since the dovetail surfaces of the buttresses are angled with respect to a vertical plane, and the angled undercut surface of the undercut edge  42  is angled with respect to a horizontal plane, the undercut edge and the dovetail buttresses combine to anchor the drain body with respect to both vertical and horizontal movement. 
     The outer sides  34  of the drain body can also include vertical darts  48  below or along the horizontal undercut  42  to improve plastic flow to thin wall sections during the molding process, as well as to add rigidity. Given their angular faces, the darts also help provide additional anchorage of the drain body in the surrounding grout material, while their small size in relation to the buttresses does not weaken the anchoring grout material between the buttresses. 
     Since it is installed using only a light friction fit and no screws or other fasteners, the drain grate  12  can be easily removed, such as by using a T-handle grate removal tool (not shown), or other suitable tool. During installation of the drain body and construction of the surrounding floor structure, a solid flat plug can be installed in the drain body in place of the grate to prevent construction debris from falling into the drain, prevent damage to the grate, and to stabilize the knife edge rim  22  of the drain body and help maintain the shape of the inlet. 
     As noted above, hair clogs are a constant challenge with drains. There are a variety of types of hair and debris traps that have been used with floor drains and other drains. Unfortunately, many of these are difficult to retrieve and remove from a drain or pipe, and can present a smelly and disgusting task to remove hair and debris tangled around steel tines, etc. 
     Advantageously, the inventor has developed a debris trap for a drain, various embodiments of which are shown in the figures. While the debris trap disclosed herein is shown in the context of a floor drain, it is to be understood that it can be used with a variety of types of drains, in addition to floor drains. As shown in  FIG. 3  one embodiment of a circular debris trap device  50  can be placed in a shallow, circular recess  28  in the floor  30  of the bowl of the drain body  10 . Viewing  FIGS. 3-7 , this debris trap embodiment  50  is a unitary piece of injection-molded plastic, and includes an annular outer ring or rim  52 , with a series of integral radial spokes or prongs  54  that extend toward the center of the ring, but leave a clear opening  56  in the middle. The circular rim  52  can include a raised protuberance  57 , disposed along an exterior edge of the rim. This protuberance helps ensure that the debris trap is placed in the drain right-side-up (i.e. with the curvature of the prongs  54  oriented upward). If the debris trap were to be placed into the recess  28  in the drain body upside down, the protuberance  57  would cause it to not lie flat and secure, thus signaling to a user to change the orientation. 
     The debris trap  50  with prongs  54  helps catch hair and other debris that drops through the drain grate  12 , without significantly obstructing the flow of water through the drain body  10 . Since hair and heavier debris will tend to drop through the outer openings of the drain grate  12 , it will tend to be washed nearer the perimeter of the bowl of the drain body, and be caught by the prongs  54  of the debris trap  50 . On the other hand, water that flows and drops straight through the center of the grate, and thus the center opening  56  of the debris trap, is believed to be less likely to include hair and other debris. 
     As noted above, in the drain embodiment shown in  FIGS. 1 and 2 , the drain grate  12  is designed to be removable just by pulling it out of the drain body  10 , allmving a user periodically to lift the debris trap out of the drain body, remove the hair and clean die debris trap, then replace the debris trap and the grate. It is to be understood, however, that the debris trap disclosed herein can be used with drains having a different configuration than that shown in  FIGS. 1 and 2 . Cleaning the debris trap is simple and straightforward. Hair and debris can be slid toward the open center  56 , where it slides off the prongs  54 . This allows easy, unrestricted removal of debris from this debris trap. 
     The prongs  54  are resilient and springy, and curved upward. Each prong has an upwardly-curved free end  58  near the center, indicated at  60 . The number, spacing, and thickness of the prongs  54  can vary. In one embodiment, a debris trap having a diameter of 3″ has been produced with 36 prongs spaced every 10 degrees, each prong being about 0.05″ wide at the distal tip  58 , and about 0.1″ wide at the base (the junction with the rim  52 ). Different numbers and sizes of prongs can be used. The size of the center opening  56  can vary also. To provide good drainage, it is desirable that the center opening be larger than about 0.5″ in diameter. In one embodiment, this opening is about 0.8″ in diameter. With a 3″ diameter debris trap and a 0.8″ diameter center opening, each prong will be less than about 1″ long, measured in the plan view. The upward curvature of the prongs can have a radius of about 0.4″ . It is to be appreciated that different curvature designs can be used, and the prongs can also be straight, with no curvature. 
     The cross-sectional shape of the prongs  54  can also vary.  FIG. 7  provides a partial sectional view of the debris trap  50  taken through some of the prongs  54 , showing one embodiment of a cross-sectional shape that can be used. In this embodiment, the prongs have a substantially flat top surface  62 , which encourages hair strands to bridge between tines rather than to pass through or between them, and a rounded or curved bottom surface  64 , which is believed to help to accelerate water flow. 
     Another embodiment of a debris trap in accordance with the present disclosure is shown in  FIGS. 8-10 . In this embodiment, the debris trap  100  comprises a cylindrical ring  102 , having a plurality of radial tines or prongs  104  extending toward its center, indicated at  106 . The prongs  104  are flexible and resilient, and curve upward toward their free ends  108  near the center. These prongs are substantially like the prongs  54  described above, and include a flat top surface  110 , a rounded bottom surface  112 , and an upwardly curved distal end  108 . 
     In this embodiment, the perimeter ring  102  of the debris trap  100  has a significantly greater vertical dimension H, and is configured to slide or snap into a corresponding cylindrical recess in a drain body (not shown). Alternatively, the debris trap  100  can be configured to fit into an opening of a circular conduit. The ring  102  provides an upwardly oriented, cylindrical flange, which press-fits into a circular recess within the drain body. This makes the debris trap more secure and stable in its installed position. The ring  102  includes a top flange  114  that helps hold the debris trap in place, and gives the debris trap a minimum diameter that is larger than the diameter of the drainage opening or conduit beyond, thus ensuring that it cannot be lost down the drain. 
     In the embodiment of  FIGS. 3-7 , the size, shape and placement of the debris trap  50  ensure that it cannot be lost down the drain and contribute to its aesthetic appeal. The debris trap sits within the circular recess  28  above the outlet of the drain body  10 . It has been found that gravity alone is sufficient to keep this embodiment of the debris trap securely in place. The diameter of the debris trap  50  is larger than the diameter of the interior of the outlet  16  of the drain body  10 , thus preventing the debris trap from being washed down the drain in any orientation. Also, because the debris trap  50  is designed to fit into a recessed pocket  28  within the drain body and below the drain grate  12 , it is substantially out of sight, thus contributing to the aesthetics of the drain installation. 
     This disclosure thus provides a simple debris trap device that is effective at trapping hair and debris in a drain, and is easy to retrieve and remove from the drain. Cleaning of the debris trap is also simple and easy. This debris trap can be injection molded as a single unitary piece, making it very economical. Indeed, the simplicity and low cost makes disposability of this type of debris trap an option. That is, rather than removing, cleaning and replacing the device periodically, a user can remove and discard the debris trap device and replace it with a new one whenever desired. 
     It is to be understood that the above-referenced arrangements are illustrative of the application of the principles of the present invention. It will be apparent to those of ordinary skill in the all that numerous modifications can be made without departing from the principles and concepts of the invention as set forth in the claims.

Technology Classification (CPC): 4