ROOF DRAIN RECEIVER

Abstract

A roof drain receiver for a site cast construction is provided comprising: a hollow main body partially buried in a wall of the construction near its bottom portion during the site casting and having one or more top inlets for receiving a number of vertical drain pipes extending interior of the construction wall to channel drain water collected from the top of the construction, and a large rectangular spout extending from the main body to an exterior side of the construction wall for emitting the channeled water off the wall. The main body has an anchoring flange for securing the same to an inner surface of the construction, a replaceable faceplate having a large rectangular opening in the center and a check door pivotally connected to the faceplate for allowing water down flowing while it normally blocks a forced entry of foreign objects into the main body.

Description

This application is a continuation of international application number PCT/US2008/007972 (publication WO2009/157900) filed Jun. 26, 2008, to same inventor Jeffrey Paul May, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

A. Field of the Invention

The present invention relates to a water drain fixture for tilt-up construction. More particularly, the present invention relates to a roof drain receiver for installation in a tilt-up building.

B. Description of the Prior Art

Prior art roof drains for conventional wood or steel framing with no cement has 16″ center to center spacing between studs. Typically, the roof drains are pipes that terminate at the base of a wall. Traditionally, a receiver has not been implemented for conventional frame buildings.

Briefly, tilt-up or tilt-slab refers to construction for factory, commercial building and the like by molding concrete wall panels on site and erecting them by a crane and securing them together with the use of studs, gussets, attachment plates, and fasteners. A roof is then constructed on top of the finished slab walls. For structural stability, various reinforcements are also built in. To maintain building functionality, a roof drain system is necessary for collecting rainwater and channeling it safely away from the tilt-up. Typical concrete tilt-up buildings have a roof drain leading to a drainpipe running down the wall interior and exiting through a cut aperture near the base of the building. The water then drips outside the building. The typical roof drainpipe terminates at a 90-degree flush cut pipe which leaves stains running down the outside of the building and also leaves a hole where debris and small animals can enter resulting in blockages and other malfunctions of the drain system.

It is known to attach a drain nozzle to the outer end of drain receiver for emitting water. However, a water-stained nozzle protruding from the building is still unsightly and may continue to invite birds and rodents. An esthetically clear and functionally advantageous solution is yet to be in existence.

SUMMARY OF THE INVENTION

According to the present invention, there are different embodiments of an improved roof drain receiver provided.

A roof drain receiver for a site cast construction according to the present invention comprises a hollow main body partially buried in a wall of the construction near its bottom portion during the site casting and having one or more top pipe sleeves for receiving a number of vertical drain pipes extending interior of the construction wall to channel drain water collected from the top of the construction, a large rectangular spout extending from the main body to an exterior side of the construction wall for emitting the channeled water off the wall and a check door pivotally connected to the spout for allowing water down flowing while it normally blocks a forced entry of foreign objects into the main body.

The main body further comprises a rectangular spout with a protruded end face partially recessed; an anchoring flange circumferentially extending in a plain perpendicular to the spout for securing the main body to an inner surface of the construction; and a faceplate having a large rectangular opening in the center, a plurality of bolt holes for accepting threaded fasteners driven though the faceplate to the protruded face of the spout, a generally U-shaped rear flange for mating internally with the recess of the protruded face, and a generally U-shaped front flange slanted downwardly for emitting drain water away from the construction.

The rectangular spout may be 3 inches long for casting into a 3 inch deep portion of the construction wall and the anchoring flange has two opposite arrays of bolt holes to permit bolts to fasten the receiver to two adjacent studs embedded in the cast construction and wherein the bolt hole arrays are spaced 16 inches apart from each other to meet the spacing of the studs so that the drain receiver is mounted in a stud bay formed by the adjacent studs.

The rectangular spout of the main body is 6 inches long for penetration through a 6 inch depth of the construction wall during the site casting to channel drain water collected from the top of the construction away from the wall through the check door pivotally connected to the spout. The drain receiver is generally made of molded plastic and the faceplate is replaceable for matching color to the exterior of the wall as well as the maintenance purpose.

The drain receiver of present invention is preferably cast in place with the building concrete tilt up wall so that it becomes a part of the wall. Because the drain receiver is integrated into the wall, the preformed structure saves the major concrete cutting process. In one embodiment, a drain receiver is provided for receiving two vertical drain pipes coming from the roof. In an alternative embodiment, there is provided a drain receiver having a single pipe connection from the roof.

On the outside, a cover is placed over the drain receiver body. The cover swings from the face of the wall in response to the outpouring of drain water. The drain receiver body lies flush with the exterior surface of the wall. The cover protrudes from the face of the wall and has a slightly overhanging lip that helps direct water away from the exterior of the wall so that the wall does not get stained from rainwater. The outside cover is interchangeable and has preferably six screws driven into the drain receiver body.

The tube sleeves are oriented substantially vertically. In the double tube embodiment, there are provided two tube sleeves, which are preferably round and spaced apart from each other opening upward. The tube sleeves can be of different diameters so that the inside surface of the tube sleeve is approximately slightly larger than the outside diameter of the roof drain pipe.

Embodiments of the invention will now be described by way of example with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a roof drain receiver according to a first embodiment of the present invention wherein a spout between the receiver body and a faceplate is shorter for application to relatively thin studs.

FIG. 2 is a rear perspective view of the faceplate of FIG. 1.

FIG. 3 is a side elevational view of the faceplate of FIG. 2.

FIG. 4 is a front view of the roof drain receiver of FIG. 1 assembled.

FIG. 5 is a cross sectional view the drain receiver taken along line 5-5 of FIG. 4.

FIG. 6 is a side elevational view of the drain receiver of FIG. 4 showing a door opened to let water out in operation of the drain receiver.

FIG. 7 is a schematic side view of a drain receiver according to a second embodiment of the present invention having a lengthened spout for application to a typical 8″ thick tilt-up wall.

FIG. 8 is a rear perspective view of a roof drain receiver according to a third embodiment of the present invention.

Similar reference numbers denote corresponding features throughout the attached drawings.

CALL OUT LIST OF ELEMENTS

10:	Drain Receiver	15:	Main Opening	25:	Back Wall
26:	Bottom Wall	27:	Slanted Wall	30, 31:	Pipe
33:	Sleeve Bevel	37:	Pipe Bottom End	40:	Main Recv Body
41:	Pipe Sleeve	42:	Receiver Outlet Slope	43:	Bolt Recv Area
44:	Main Body Flange	45:	Spout	46:	Lower Bevel
47:	U-shaped Recess	48:	Receiver Top Opening	49:	Body Liner
50:	Door	51:	Pivot Arm Opening	52:	Door Pivot Arm
55:	Gasket	56:	Pivot Pin	57:	Pivot Hole
58:	Gasket Bolt Hole	59:	Opening	61:	Face Plate Flange
62:	Face Plate Rear Flange	63:	Faceplate	64:	Flange Sidewall
65:	Overhang	66:	Rear Flange Sidewall	67:	Face Plane
68:	Bolt Hole	69:	Hinge Portion	70:	Notch
78:	Bore	88:	Screw	90:	Wall
100:	Drain Receiver	120:	Outlet Frame	140:	Receiver Body
141:	Pipe Sleeve	144:	Front Opening	145:	Screw Holes
146:	Spout	148:	Top Wall	149:	Bottom Wall
150:	Outlet Slope	152:	Exterior Side	154:	Tilt-up Wall
156:	Channel Bracket	158:	Clamp Half	160:	Eyelet
162:	Pipe Sleeve	165:	Cutout	166:	Sidewall Recess
200:	Drain Receiver	230:	Single Pipe	240:	Main Body
241:	Pipe Sleeve	244:	Anchoring Flange	245:	Screw Hole
265:	Door Stop

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a drain receiver 10 according to a first embodiment of the present invention has a main body 40 molded of plastic material such as PVC used to fabricate drainpipes in the shape of a frontally open box. In this embodiment, body 40 is wide enough to mount two typical drainpipes 30, 31 side by side on its top surface, which has two vertical pipe sleeves 41. Drain receiver 10 is adapted to be cast into a 3″ deep wall portion of 6″ total wall depth of the wall as shown in FIG. 6 where receiver 10 is to be fastened primarily to wood or steel studs embedded in the wall. The wall may have a standard stud spacing of 16″ measured between adjacent stud centers. So, drain receiver 10 is appropriately designed for mounting in the stud bay formed between the studs.

Pipe sleeves 41 have inwardly slanted bevels 33, respectively for easily introducing bottom ends 37 of pipes 30, 31 into sleeves 41. In comparison, the bottom of main body 40 may slant up in the back but descends in the front to let water from vertical pipes 30, 31 flows through main body 40 fast and easy. In order to provide a broad attachment surface, a main body flange 44 is formed integrally to the junction between main body 40 and a spout 45. Spout 45 may be 3″ long measured from flange 44 and put in the mold for forming a wall 90 of 3″ depth. Flange 44 may be rectangular in proportion to main body 40 and has three screw holes 145 along each of the lateral sides. At attachment, the front surface of flange 44 will bear against two adjacent studs buried in the construction wall to which screws (not shown) are driven from behind flange 44.

Protruding centrally of flange 44, spout 45 surrounds a front rectangular opening 144 of main body 40. Generally rectangular flange face 120 extends between spout 45 and front opening 144 to form a protruded base to which a removable faceplate 63 is fastened. To make a waterproof engagement with faceplate 63, protruded face 120 is partially withdrawn along its lower inner sides to form a U-shaped flange recess 47 with two opposite sidewall recesses 166 that receive a rear flange 62 and its lateral extension of two sidewalls 66 protruding rearward of faceplate 63. At approximately even intervals, flange face 120 has six bores 78 for accepting screws for attaching faceplate 63. Faceplate 63 has six bolt holes 68 at the corresponding locations to bores 78 of flange face 120. Faceplate 63 may be sized to overhang all around flange face 120 constituting a front vertical flange as opposed to the flange 44 in the back. Between two flanges 44 and 63, a surrounding construction wall will be interposed to secure drain receiver 10 in place.

Faceplate 63 also has a wide rectangular opening 15 in the center, which is closed by a rectangular swivel door 50. Upwardly of sidewalls 66, faceplate 63 has hinge arms 69 as shown clearly in FIGS. 2 and 3 while door 50 has two L-shaped pivot arms 52 with pivot holes 57 formed on the rear upper corners of door 50 so that via pivot pins 56 arms 52 and 69 are connected so that door 50 is hung on its own weight from faceplate 63 normally closing the opening 15. There are two door stops 265 formed inwardly of sidewalls 66 of faceplate 63. In order to receive door stops 265, two opposite small cutouts 165 are provided on face 120 merging with flange recess 47 inwardly thereof to accommodate two door stops 265 when faceplate 63 is attached to flange face 120.

Extending flush with the bottom side of opening 15, a short downwardly slanted flange 61 spans almost the full length of faceplate 63 and terminates at opposite ends with small sidewalls 64. Thus formed faceplate 63 assembled with door 50 may be attached by screws 88 to face 120 of body flange 44 with a soft gasket 55 interposed therebetween. Gasket 55 is sized and shaped in conformity to flange face 120 having bolt holes 58 at aligned positions with bolt holes 68 of faceplate 63 and bores 78 of flange face 120. Gasket 55 also has a larger opening 59 formed at its lower side to expose U-recess 47 so that rear flange 62 and sidewalls 66 of faceplate 63 may pass. Openings 51 in gasket 55 conform to notches 70 of flange face 120 for letting pivot arms 52 to penetrate.

Turning now to the front view of FIG. 4, the door 50/faceplate 63 assembly is generally centrally positioned in front of main body flange 4. Door 50 lies flush with faceplate 63 within wide opening 15 with a slight clearance therebetween. Depending freely from hinge arms 69 of faceplate 63, door 50 is prevented from being pushed in by two stops 265 described above to keep off unwelcome creatures. However, whenever water drops through pipes 30 and 31 door 50 opens in response to the amount of water to open to just a degree as necessary for the draining purpose. The fall of slanted flange 61 is obvious in this drawing.

The structure of drain receiver 10 of the present invention will be better understood with reference to FIG. 5 wherein pipe 30 is held in pipe sleeve 41, which extends upwardly of receiver body 40 leaving a top opening 48 in the center of sleeve 41. The penetration of pipe 30 may be limited by having sleeve 41 converge at a lower bevel 46 that merges into the smaller diameter of top opening 48 compared to the inner diameter of sleeve 41. So, bottom end 37 of pipe 30 may rest on bevel 46. Yet, top opening 48 is larger than the inner diameter of pipe 30 not to interfere with the natural flow of drain water.

Supporting pipe sleeve 41, receiver body 40 mainly comprises a longitudinal back wall 25 and a latitudinal bottom wall 26 connected to back wall 25 via a slanted wall 27 extending at a descending angle such as 45 degrees. Bottom wall 26 continues at a slightly descending angle to an outlet slope 42 that extends into the opening 144 defined by spout 45. Spout 45 has an ample thickness to constitute a bolt receiving area 43 to support faceplate 63 and door 50 together. A plastic body liner 49 may be optionally put in receiver body 40 to partially cover the same against a contamination buildup over time. At the time of replacing faceplate 63, liner 49 may be changed also. Body liner 49 further extends to cover outlet slope 42 terminating short of door 50 so that the drain water entering receiver body 40 flows down to meet door 50, which readily opens outwardly about pivot arm 52.

Faceplate 63 attached to spout 45 with gasket 55 interposed therebetween provides an overhang 65 that extends along the exterior of spout 45. Therefore, drain receiver 10 with pipes 30, 31 inserted may be placed in a relatively thin wall area during concrete casting of the wall, which will be sandwiched between main body flange 44 and overhang 65 to solidly hold receiver 10 in place. Then, drain receiver 10 may be secured to the set concrete wall by driving bolts through screw holes 145 (FIG. 4) aligned to studs, which are integrated with the wall during the casting. A face plane 67 represents the exterior of the construction on which faceplate 63 abuts. In another embodiment of the present invention, spout 45 may be long enough to be embedded in an 8″ thick wall leaving the same faceplate 63 and door 50 laid flat on the outer surface of the building.

FIG. 6 shows the operation of the drain receiver 10 installed to provide the gated exit of drain water. The receiver 10 of the present invention provides a neat appearance of the building exterior by its thin profile due to the function of door 50. And the streamlined internal passage of water and the guiding flange 61 advantageously isolate discharged water to help maintain the building free of water stain and save a cleaning labor.

Although FIG. 1-6 relate to conventional stick built walls made of wood or steel studs, the thin profile could also be applied to a concrete wall, where the concrete wall has a hollow area of approximately the same dimensions as a stick built wall hollow area.

Therefore, the drain receiver can be adapted for thin concrete wall applications also. The PVC and ABS materials are preferred for the drain body in wood or steel frame applications. And a metal such as iron or cast bronze is preferred for concrete tilt up applications.

FIG. 7 illustrates a drain receiver 100 according to a second embodiment of the present invention adapted to cast on site into a thick tilt-up wall. Because drain receiver 100 will become a part of the strong concrete wall body along a substantial depth flange 44 of receiver 10 may be omitted. A receiver body 140 comprises a pipe sleeve 141, longitudinal back wall 25 and a latitudinal bottom wall 149 connected to back wall 25 via slanted wall 27 extending at a descending angle such as 45 degrees. In this embodiment, receiver 100 has an extended spout 146. Spout 146 has a face structure similar to the flange face 120 shown in FIG. 1 in order to be compatible with faceplate 63. Spout 146 has a top wall 148 of an even general thickness while the bottom wall 149 is gradually thinned to provide a downward water chute until it turns into an even more slanted outlet slope 150 resting on rear flange 62 of faceplate 63.

From faceplate 63, multiple screws 88 are driven into spout 146 through gasket 55 to secure faceplate 63, which lies thin and flat on an exterior side 152 of a typical 8″ thick tilt-up wall 154. Extending flush within the frame of faceplate 63 is door 50 hinged to the upper side of face structure 146. The rectangular spout 146 may have four concrete anchor tabs (not shown) that slightly protrude from the respective sides of spout 146. On the interior surface of wall 154, a unistrut pipe fixture may be used wherein a channel interlocking bracket 156 is horizontally attached to wall 154 and a pair of clamp halves 158 are slidably held in bracket 156 to clamp each received pipe 30 cooperatively. To permanently secure pipe 30, clamp halves 158 may have side eyelets 160 aligned for threading a bolt that binds two clamp halves 158 around pipe 30. Along the height of pipe 30 over the wall 154 there may be multiple similar fixtures for stability.

Drain receiver 100 may be dimensioned to have two of pipe sleeves 162 side by side for receiving pipes 30 at a preferable distance of about ⅞″ from the wall 154. Hence, channel bracket 156 is preferably selected to extend the same ⅞″ or less from wall 154 to pipe 30.

FIG. 8 shows the rear of a drain receiver 200 according to a third embodiment of the present invention wherein a main body 240 is similarly shaped into a frontally open box. Main body 240 is virtually identical to the main body 40 of receiver 10 of the first embodiment except that it has a scaled down horizontal dimension including a width just enough to mount a single pipe 230 on its top surface with a pipe sleeve 241 and the correspondingly narrowed spout (not shown) in the front. Still, main body 240 may have a large anchoring flange 244 with three vertically aligned screw holes 245 at each of the lateral sides thereof with 16″ distance between the two sides of holes 245.

Drain receiver 200 may be made for a relatively short 3″ application that is designed primarily for wood or steel studs. Alternatively, the receiver 200 may be modified to have a longer spout similar to receiver 100 of the second embodiment to make a single pipe wall cast receiver that has the same advantage of the present invention. As in the case with the second embodiment, the longer spout may obviate the need for flange 244.

Although FIG. 7-8 relate to a tilt up wall made of concrete, it could also be applied to a variety of constructions where the wall is thick, such as hay bale construction where the wall has a substantial thickness of approximately the same dimensions as a tilt up wall. Therefore, the tilt up version of the drain receiver can be adapted for thick traditional wall applications also. Again, PVC and ABS materials are preferred for the drain body in wood or steel frame applications, and a metal such as iron or cast bronze is preferred for concrete tilt up applications.

Therefore, while the presently preferred form of the tilt-up roof drain receiver has been shown and described, and several modifications thereof discussed, persons skilled in this art will readily appreciate that various additional changes and modifications may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.

Claims

1. A roof drain receiver for a site cast construction comprising:

a hollow main body partially engaged in a wall, near a wall bottom portion of a building during site casting and having one or more top pipe sleeves for receiving a number of vertical drain pipes extending interior of the building wall to channel drain water collected from the top of the building, a large rectangular spout extending from the main body to an exterior side of the building wall for emitting the channeled water off the wall and a check door pivotally connected to the spout for allowing water down flowing while it normally blocks a forced entry of foreign objects into the main body.

2. The roof drain receiver of claim 1, wherein the main body further comprises a rectangular spout with a protruded end face partially recessed; an anchoring flange circumferentially extending in a plain perpendicular to the spout for securing the main body to an inner surface of the construction; and a faceplate having a large rectangular opening in the center, a plurality of bolt holes for accepting threaded fasteners driven though the faceplate to the protruded face of the spout, a generally U-shaped rear flange for mating internally with the recess of the protruded face, and a generally U-shaped front flange slanted downwardly for emitting drain water away from the construction.

3. The roof drain receiver of claim 2, wherein the rectangular spout extends a 3 inch length for casting into a 3 inch deep portion of the construction wall and the anchoring flange has two opposite arrays of bolt holes to permit bolts to fasten the receiver to two adjacent studs embedded in the cast construction and wherein the bolt hole arrays are spaced 16 inches apart from each other to meet the spacing of the studs so that the drain receiver is mounted in a stud bay formed by the adjacent studs.

4. The roof drain receiver of claim 1, wherein the rectangular spout of the main body is 6 inches long for penetration through a 6 inch depth of the construction wall during the site casting to channel drain water collected from the top of the construction away from the wall through the check door pivotally connected to the spout.

5. A roof drain receiver of claim 1, wherein the drain receiver is generally made of cast bronze.

6. A roof drain receiver of claim 1, wherein the drain pipes are supported by a unistrut pipe fixture including a channel interlocking bracket horizontally attached to the wall and a pair of clamp halves slidably held in the bracket to clamp each received pipe cooperatively and wherein the pipe sleeves are located at a predetermined distance from the wall.

7. A roof drain receiver of claim 6, wherein the pipe sleeve has a distance of ⅞″ from the wall to position the pipe fixture therebetween.

8. A roof drain receiver for a stick built building construction comprising:

a hollow main body engaged in a wall of the construction near a wall bottom portion attached between studs of a building wall;

top pipe sleeves for receiving a number of vertical drain pipes extending interior of the building wall to channel drain water collected from the top of the building, a large rectangular spout extending from the main body to an exterior side of the building wall for emitting the channeled water off the wall and a check door pivotally connected to the spout for allowing water down flowing while it normally blocks a forced entry of foreign objects into the main body.

9. The roof drain receiver of claim 8, wherein the main body further comprises a rectangular spout with a protruded end face partially recessed; an anchoring flange circumferentially extending in a plain perpendicular to the spout for securing the main body to an inner surface of the construction; and a faceplate having a large rectangular opening in the center, a plurality of bolt holes for accepting threaded fasteners driven though the faceplate to the protruded face of the spout, a generally U-shaped rear flange for mating internally with the recess of the protruded face, and a generally U-shaped front flange slanted downwardly for emitting drain water away from the construction.

10. The roof drain receiver of claim 8, wherein the roof drain receiver is made of molded plastic and the faceplate is replaceable for matching color to the exterior of the wall as well as for maintenance.

11. A roof drain receiver for a wall comprising:

a hollow main receiver body having;

at least one top pipe sleeve extending upward from the hollow main receiver body,

wherein the top pipe sleeve is adapted to receive a member of vertical drain pipes to channel drain water collected from the top of the building;

a large rectangular spout extending from the main body to an exterior side of the building wall, wherein the main receiver body forms an approximately 90° bend for directing channeled water away from the wall;

a check door pivotally connected to a flange; and

a generally U-shaped rear flange for mating internally with the recess of a protruded face, and a generally U-shaped front flange slanted downwardly for directing drain water away from the construction.

12. The roof drain receiver of claim 11, wherein the roof drain receiver is made of molded plastic and the faceplate is replaceable for matching color to the exterior of the wall as well as for maintenance.

13. The roof drain receiver of claim 11, wherein the check door has a pair of pivot arms that connect to hinge portions mounted on a faceplate, wherein the faceplate is mounted to a main flange formed on the hollow main receiver body, wherein the hinge portions it into hinge portion notches formed on the hollow main receiver body.

14. The roof drain receiver of claim 13, further comprising a gasket fitting between an outlet frame and a faceplate, wherein the gasket is basically rectangular and has bolt holes for receiving bolts and forming a water tight seal between the outlet frame and the faceplate.

15. The roof drain receiver of claim 14, wherein the roof drain receiver is made of molded plastic and the faceplate is replaceable for matching color to the exterior of the wall as well as for maintenance.

16. The roof drain receiver of claim 14, wherein the roof drain receiver is made of metal and is cast in place to a concrete tilt-up wall.

17. The roof drain receiver of claim 16, wherein the check door has a pair of pivot arms that connect to hinge portions mounted on a faceplate, wherein the faceplate is mounted to a main flange formed on the hollow main receiver body, wherein the hinge portions it into hinge portion notches formed on the hollow main receiver body.

18. The roof drain receiver of claim 17, further comprising a gasket fitting between an outlet frame and a faceplate, wherein the gasket is basically rectangular and has bolt holes for receiving bolts and forming a water tight seal between the outlet frame and the faceplate.