Floor drain assembly system and method of forming the same

• US 9,567,739 B2
• Filed: 03/31/2015
• Issued: 02/14/2017
• Est. Priority Date: 04/01/2014
• Status: Active Grant

• Current Assignee: Surepods LLC
• Original Assignee: Oldcastle Precast Incorporated (CRH PLC)
• Inventors: Nyce, Daniel
• Primary Examiner(s): Michener, Joshua J
• Assistant Examiner(s): AKBASLI, ALP A
• Application Number:
  US14/674,376
• Publication Number:
  US 20150275497A1
• Time in Patent Office: 686 Days
• Field of Search: 523/021, 523/027
• US Class Current: 1/1
• CPC Class Codes: E03F 5/0407 Floor drains for indoor use
• CPC Class Codes: E03F 5/0409 Devices for preventing seepage around the floor drain

Abstract

Flooring and drain assemblies are provided. The assemblies provide a plurality of panels or flooring members for surrounding and directing fluid toward a drain body. Assemblies include a drain body may be secured to or in fluid communication with additional plumbing features, and layers or features for connecting the assembly. The drain body is connected to at least one the flooring members in various ways to promote proper floor drainage.

Claims

1. A drain assembly for a gravity fed floor drain, the assembly comprising:

a lower subfloor panel and an upper subfloor panel, the lower subfloor panel and the upper subfloor panel secured together by an adhesive layer provided therebetween;

a drain member comprising a drain outlet extending downwardly into the upper subfloor panel and the lower subfloor panel, and a flange extending laterally away from the drain outlet over at least a portion of the lower subfloor panel;

a drain cover operable to be selectively secured to at least one of the drain member and the flooring surface;

a flooring surface comprising a material that is substantially non-permeable to liquids, the flooring surface surrounding and extending outwardly away from the drain member, and wherein the flooring surface comprises a first slope and a second slope;

wherein the upper subfloor panel comprises a bisected honeycomb panel member provided between the flooring surface and the lower subfloor panel, the bisected honeycomb panel member operable to provide a tapered slope to the flooring surface in an assembled state;

wherein at least a portion of the flooring surface extends over at east a portion of the flange of the drain member, and wherein at least a portion of the flooring surface is compressed beneath the drain cover and secured to the flange by an adhesive; and

the first slope provided at a location distal to the drain member, and the second slope provided at a location proximal to the drain member.

2. The drain assembly of claim 1, wherein the first slope comprises a substantially horizontal floor surface and the second slope comprises an angle extending downwardly toward the drain outlet.

3. The drain assembly of claim 1, further comprising fasteners securing the drain cover to the drain member and wherein the flooring surface is compressed between the drain cover and the drain member.

4. The drain assembly of claim 1, wherein the adhesive layer comprises at least one of epoxy, vinyl glue, and adhesive tape.

5. The drain assembly of claim 1, wherein the flooring surface comprises at least one of vinyl, tile, stone, and high build epoxy coating.

6. A drain assembly for a gravity fed floor drain, the assembly comprising:

a lower subfloor panel and an upper subfloor panel, the lower subfloor panel and the upper subfloor panel secured together by an adhesive layer provided therebetween, wherein at least one of the upper subfloor panel and the lower subfloor panel comprise a bisected honeycomb;

a drain member comprising a drain outlet extending downwardly beyond the lower subfloor panel, and a flange extending laterally away from the drain outlet over at least a portion of the lower subfloor panel, wherein a lower portion of the flange is adhered to the lower subfloor panel;

a flooring surface surrounding and extending outwardly away from the drain member;

wherein at least a portion of the flooring surface extends over at least a portion of the flange of the drain member to promote drainage toward the drain outlet, and wherein the portion of the flooring surface is adhered to an upper portion of the flange; and

a drain cover operable to cover at least a portion of the drain member and wherein the drain member is secured to at least one of the flange, the upper subfloor assembly, and the lower subfloor assembly by at least one fastener.

7. The drain assembly of claim 6, wherein the flange of the drain member is secured directly to the drain cover by the at least one fastener.

8. The drain assembly of claim 6, wherein the drain cover is disposed above the drain outlet and at least a portion of the flooring surface.

9. The drain assembly of claim 6, wherein the adhesive layer comprises at least one of epoxy, vinyl glue, and adhesive tape.

10. The drain assembly of claim 6, wherein the flooring surface comprises at least one of vinyl, tile, stone, and high build epoxy coating.

11. The drain assembly of claim 6, wherein the drain outlet comprises a male threaded member for securing the drain outlet to a plumbing feature.

12. A drain assembly for a gravity fed floor drain, the assembly comprising:

an upper subfloor panel and a lower subfloor panel, the upper subfloor panel and the lower subfloor panel secured together by an adhesive layer;

at least one of the upper subfloor panel and the lower subfloor panel comprising a bisected honeycomb panel member;

a drain body comprising an upper portion and a lower portion, the upper portion comprising a flange extending outwardly and laterally away from a drain outlet over at least a portion of the lower subfloor panel, the subfloor panel comprising a cutout having a predetermined shape for receiving at least a portion of the drain body;

at least a portion of an underside of the flange secured to the lower subfloor panel;

a flooring surface comprising a material that is substantially non-permeable to liquids provided on the upper subfloor panel, the flooring surface extending outwardly away from the drain member, and wherein the flooring surface comprises a first slope and a second slope;

a drain cover operable to be selectively secured to at least one of the drain member and the flooring surface;

wherein at least a portion of the flooring surface extends over an outer edge of the flange and is secured to an upper portion of the flange by at least one of an adhesive and a bonding agent;

wherein at feast a portion of the flooring surface is compressed between the drain cover and the flange when the drain cover is provided in an assembled state;

wherein a lower portion of the flange is secured to the lower subfloor panel by a bonding agent;

the first slope provided at a location distal to the drain member, and the second slope provided at a location proximal to the flange, and wherein a tapered slope is provided between the first slope and the drain outlet;

wherein the second slope is provided at least partially over the flange and is greater than the first slope to promote drainage into the drain member.

13. The drain assembly of claim 12, further comprising a waterproofing membrane provided between the flooring surface and the drain member.

14. The drain assembly of claim 12, wherein the upper subfloor panel comprises a bisected honeycomb panel member provided between the flooring surface and the lower subfloor panel.

15. The drain assembly of claim 12, wherein a portion of the underside of the flange is secured to the lower subfloor panel by an adhesive layer, the adhesive layer comprising at least one of epoxy, vinyl glue, and adhesive tape.

16. The drain assembly of claim 12, wherein the flooring surface comprises at least one of vinyl, tile, stone, and high build epoxy coating.