Floor Through Assembly with Adjustable Drain

Abstract

A trough assembly with adjustable drain is provided. The trough assembly is designed to address seepage problems associated with traditional drain and trough industry standard installation methods. The trough assembly includes a drain assembly. The drain assembly includes a seepage flange. The seepage flange includes a collar having open-ended slots. These slots are configured to cooperate with coupling protrusions to allow for adjustability of the drain assembly. This adjustability allows for accommodation of construction errors, including, but not limited to, variations in the elevation of the finished floor elevation. The seepage flange is also configured to collect seepage fluids into the central aperture of the drain assembly.

Description

PRIORITY CLAIM

This application claims the benefit of U.S. Provisional Patent Application No. 61/218,356, filed Jun. 18, 2009, which is hereby incorporated herein by reference.

BACKGROUND

The present disclosure relates generally to the field of floor troughs and drains. More particularly, the present disclosure relates to a floor trough assembly with an adjustable drain designed to address seepage problems associated with traditional drain and trough industry standard installation methods.

Drains and floor troughs are typically installed in a space in which fluid would commonly be found on the floor of the space. For instance, drains and troughs are often installed in spaces used for industrial applications, rainwater runoff applications, laboratories, food service, preparation areas, cook lines, dish rooms, back bar areas, and kettle and tilt skillet areas. Drains and troughs provide a means to effectively remove fluids from these spaces and direct these fluids to the plumbing of a building. Fluids that enter a drain or trough exit the building via the plumbing system.

When using traditional drain and trough industry standard installation methods, some fluids may not enter the drain or trough; instead these fluids seep into the floor of the space, often through cracks and seams. For example, the seam between the floor trough and flooring can be particularly problematic if it weakens over time allowing fluids a path to seep into the floors rather than through the trough or drain. These seepage fluids may leak through the floor into spaces below. When this happens, the fluids may damage or interfere with the contents of the space or the structure of the space itself.

It would be advantageous to provide a floor trough assembly that prevents seepage problems and efficiently collects fluids. It would further be advantageous to provide a floor trough with an adjustable drain to accommodate variations in the height of a floor. It would further be advantageous to provide a floor trough with an adjustable drain that may be installed quickly and accurately.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a cross-sectional view of a trough assembly according to a first exemplary embodiment installed in a floor.

FIG. 2 is a perspective exploded view of the drain of the trough assembly of FIG. 1.

FIG. 3 is a perspective exploded view of the trough assembly of FIG. 1.

FIG. 4 is a detailed view of the trough assembly of FIG. 1 taken along line 4-4.

FIG. 5 is a perspective view of a drain of a trough assembly according to a second exemplary embodiment.

FIG. 6 is a partial perspective exploded view of the trough assembly of FIG. 5.

FIG. 7 is a perspective view of the drain assembly of FIG. 5 assembled.

FIG. 8 is a partial perspective exploded view of the trough assembly of FIG. 5 having a shorter seepage flange.

FIG. 9 is a cross-sectional view of the drain of FIG. 8 having a shorter seepage flange.

DETAILED DESCRIPTION

Referring to the FIGURES in general, a floor trough assembly with an adjustable drain, shown as trough assembly 10, and/or components thereof are shown according to various exemplary embodiments. Trough assembly 10 is configured to prevent seepage problems associated with traditional floor trough installations and installation methods.

FIG. 1 shows trough assembly 10 is shown installed in a floor 12 of a structure, such as a building. A waste pipe links trough assembly 10 to the conventional plumbing system or waste removal system (not shown) of the structure. Floor 12 may be above a space used for any number of purposes. Trough assembly 10 is configured to capture fluids that pass into the floor 12 and efficiently remove the fluids through the conventional plumbing system, preventing the fluids from leaking into the space below. Accordingly, trough assembly 10 prevents potentially costly repairs to building interiors, finished ceilings, etc. Further, by capturing seepage fluids, reinstallation the trough assembly itself may be avoided.

Trough assembly 10 is also configured to be adjustable in order to accommodate variations in floor 12. Referring to a first exemplary embodiment shown in FIGS. 1 and 2, trough assembly 10 includes an upper assembly 14 positionable relative to a lower assembly 16. Upper assembly 14 may be adjusted along a central axis 18 relative to lower assembly 16. Upper assembly 14 may also be rotated about central axis 18 relative to lower assembly 16. In this manner, trough assembly 10 is vertically and rotatably adjustable to accommodate variations in floor 12.

Trough assembly 10 is particularly well suited for food service and other industrial applications including but not limited to slaughterhouses, food processing factories, supermarket food preparation areas, movie theater concessions areas, laboratories and even rain water runoff applications. Gaps and crevices between a trough assembly and a floor can trap fluids, trap debris, and breed bacteria. Gaps and crevices between trough assembly 10 and floor 12 are substantially avoided because trough assembly 10 can accommodate variations in floor 12, providing a cleaner and safer space. While trough assembly 10 is discussed as being particularly well suited for food service and other industrial applications, it should be understood that one or more of the features disclosed herein may be used in a variety of applications where efficient disposal of seepage fluids and cleanliness is desirable (e.g., slaughter houses, food processing factories, movie theaters, laboratories, etc.).

Further referring to FIGS. 1 and. 2, upper assembly 14 includes a drain bowl 20 and a trough or trough pan 22 defining a reservoir 24. Lower assembly 16 includes a sump drain 26 and a seepage flange 28. When assembled, sump drain 26, seepage flange 28, and drain bowl 20 define a drain 30 having a central aperture 32. Central aperture 32 extends substantially along central axis 18 from trough pan 22 to the waste removal system. Fluids collected by trough assembly 10 flow into and through the central aperture 32 to exit through the plumbing system.

Sump drain 26 is configured to couple trough assembly 10 to the waste removal system, providing for removal of fluids captured by trough assembly 10. Sump drain includes a sump drain rim 34 and a sump drain body 36. Sump drain rim 34 extends radially outward from the top of sump drain body 36. In the exemplary embodiment shown, sump drain body 36 is shown having a bowl-shaped upper portion above a substantially annular lower portion configured to be coupled to the plumbing system. Sump drain 26 further includes a coupling feature shown as studs 38 configured to couple sump drain 26 to seepage flange 28. Studs 38 are shown as cylindrical protrusions that extend substantially vertically upward parallel to central axis 18 from the top of the sump drain rim 34 and substantially perpendicular thereto. Ideally, the studs 38 are welded to the sump drain rim 34 which maintains the water impervious nature of the rim 34.

Seepage flange 28 is configured to receive drain bowl 20. Seepage flange 28 is further configured to be coupled to sump drain 26. Seepage flange 28 includes a seepage flange collar 44 and a seepage flange rim 46. Seepage flange rim 46 extends radially outward from the bottom of the seepage flange collar 44 and includes an first portion 48, a second portion 50, and a plurality of weep holes 52. First portion 48 is angled between the bottom of seepage flange collar 44 and second portion 50. Second portion 50 is substantially perpendicular to central axis 18. Seepage flange rim 46 further includes coupling features shown as a plurality of holes 54 sized to receive studs 38 of sump drain 26.

Seepage flange collar 44 extends substantially vertically upward from seepage flange rim 46 along central axis 18. Seepage flange collar 44 is configured to provide for the vertical and rotational adjustability of upper assembly 14 relative to lower assembly 16. Seepage flange collar 44 receives drain bowl 20 when drain 30 is assembled. Drain bowl 20 may be moved along central axis 18 within seepage flange collar 44. Drain bowl 20 may further be rotated about central axis 18 within seepage flange collar 44.

Drain bowl 20 is configured to be coupled to seepage flange 28. Drain bowl 20 includes a drain bowl rim 60 and a drain bowl body 62. Drain bowl rim 60 extends substantially radially outward from the top of drain bowl body 62 and defines an upper opening 64. As discussed above, drain bowl body 62 is configured to be received in the seepage flange collar 44.

Trough pan 22 includes a top side 66 that is substantially open and a bottom side 68 opposite top side 66. Trough pan 22 is configured to collect fluids from at or above floor 12 within reservoir 24. Bottom side 68 includes an opening 70 (see, e.g., FIG. 1 illustrating opening 70) corresponding to upper opening 64 of drain bowl 20. Trough pan 22 further includes a peripheral wall 72 extending between top side 66 and bottom side 68. In the exemplary embodiment shown, peripheral wall 72 is rectangular.

Trough pan 22 may further include an edge (e.g., rim, lip, projection, etc.) shown as a flanged edge 74 extending outward from peripheral wall 72 at top side 66 of trough pan 22. Flanged edge 74 is configured to secure trough pan 22 to floor 12 and prevent weakening of and formation of cracks about trough assembly 10 once installed. Flanged edge 74 includes a plurality of holes (e.g., apertures, openings, etc.) shown as grout-locking holes 76. Grout-locking holes 76 are configured to allow grout or another flooring material to pass through during installation. Grout-locking holes 76 prevents cracks, which frequently serve as leak points for water and weaken the installation of trough assembly 10 in floor 12. Flanged edge 74 further includes an outer portion 78. Outer portion 78 is a distance below the top surface of floor 12 and covered (e.g., embedded, held down, buried, etc.) beneath flooring material when installed, helping to secure trough assembly 10 to within floor 12.

Trough assembly 10 may further include a grate 84 at the top side 66 of trough pan 22. In the exemplary embodiment shown, peripheral wall 72 of trough pan 22 includes an interior ledge 86 (i.e., mantle, shelf, offset, projection, step, tier, etc.) configured to receive grate 84. Interior ledge 86 also substantially prevents back and forth and side-to-side movement of grate 84 relative to trough pan 22 and floor 12. Grate 84 includes a plurality of apertures 88 configured to allow fluids to pass into trough pan 22. Grate is configured to be non-slip, removable, and anti-fatigue. Persons can freely walk on top of grate 84. Thus, grate 84 does not substantially inhibit typical uses of the floor in which trough assembly 10 is installed. Grate 84 is depicted made of fiberglass, however, a person of skill in the art would recognize that the grate may be made of other suitable materials.

Referring to FIG. 3, drain bowl 20 and trough pan 22 are coupled before assembly and installation. Drain bowl 20 is coupled to bottom side 68 of trough pan 22 at drain bowl rim 60. Opening 70 at bottom side 68 of trough pan 22 substantially corresponds to upper opening 64 of drain bowl 20. According to one exemplary embodiment, drain bowl rim 60 is welded to bottom side 68 of trough pan 22; however, according to other exemplary embodiments, drain bowl 20 and trough pan 22 may be coupled according to any method known in the art (e.g., drain bowl 20 and trough pan 22 may be integrally formed).

Referring back to FIGS. 1-2, the assembly and installation of trough assembly 10 will be discussed. A first flooring layer, shown as slab 100, is first poured and set. Slab 100 defines a depression 102 (i.e., cavity, compartment, hole, etc.) configured to accommodate trough assembly 10. In the embodiment shown depression 102 extends at least to a minimum depth at all points beneath trough pan 22. Typically, the minimum depth accounts for the depth of trough pan 22 and other trough assembly components as installed. Depression 102 includes a cavity 104 (e.g., penetration, hole, aperture, etc.). Cavity 104 extends to a depth greater than the minimum depth to receive sump drain 26. Slab 100 is shown as concrete, however, in other exemplary embodiments, the first flooring layer may be any of a number of flooring or foundation materials known in the art. It should be noted that trough pan 22 may be provided having any number of depths (e.g., related to the thickness of floor 12 and the purposes for which it will be used). Also, in other exemplary embodiments the depression in the slab may have any of a number of shapes and depths (e.g., corresponding the configuration of the trough assembly to be installed).

According to one exemplary method of installation, a recess 106 is provided about the perimeter of cavity 104. Recess 106 is shown configured to receive sump drain rim 34 therein. In this manner, recess 106 is configured to prevent damming of fluids and promote positive pitch and flow of fluids into weep holes 52. Recess 106 may be formed, for example, by grinding the surrounding slab According to other exemplary embodiments, the recess may extend to a variety of depths, (e.g., to also accommodate the seepage flange rim and/or a waterproof membrane) or may not be present.

Sump drain 26 is received in cavity 104 and coupled to the waste removal system of the space/building in which trough assembly 10 is located. Sump drain 26 is substantially aligned along central axis 18. Sump drain rim 34 is substantially perpendicular to central axis 18 and received by recess 106.

Referring to FIG. 4, trough assembly 10 may further include a membrane 110 shown as a water proof membrane (e.g., Bituthene 3000). Membrane 110 is configured to prevent water from passing through to lower portions of the floor. Membrane 110 is further configured to direct fluids that have seeped or leaked into floor 12 towards trough assembly 10 for collection and disposal through the plumbing system. Membrane 110 generally has a central opening 112 configured to substantially correspond to a top opening 114 of sump drain 26 substantially defined by sump drain rim 34. Membrane 110 substantially covers sump drain rim 34 and extends outward therefrom to cover slab 100 in the area (e.g., space, room, etc.) surrounding trough assembly 10 and substantially lining depression 102. Membrane 110 may be secured (e.g., affixed, bonded, etc.) to the exposed surfaces of slab 100 using an adhesive. Membrane is generally a sheet-type or roll-type material so that it may be pinched (i.e., clamped, fixed, secured, etc.) between sump drain 26 and seepage flange 28. Although, in other exemplary embodiments, the membrane may be a troweled on membrane.

Seepage flange 28 is coupled to sump drain 26. Second portion 50 seepage flange rim 46 substantially corresponds to sump drain rim 34 and is parallel or flush thereto. Holes 54 of seepage flange rim 46 are positioned over studs 38. Fasteners shown as nuts 116 are received by studs 38, securing seepage flange rim 34 to sump drain 26. Membrane 110 is pinched between second portion 50 of seepage flange rim 46 and sump drain rim 34. Membrane 110 is received in recess 106 and positioned such that fluids will be guided through weep holes 52 into central aperture 32 for removal. Weep holes 52 are located or aligned above top opening 114 of sump drain 26. Accordingly, fluids entering weep holes 52 flow directly into central aperture 32 of drain 30. By avoiding holes in sump drain rim 34, there is little opportunity for fluids to exit to the exterior of drain 30 from central aperture 32 or leak past membrane 110. In other exemplary embodiments, however, the seepage flange and the sump drain may be coupled according to other methods known in the art.

Referring back to FIGS. 1-2, upper assembly 14 is coupled to seepage flange 28. Drain bowl 20 is positioned into seepage flange collar 44 In the exemplary embodiment shown, drain bowl 20 is positioned in seepage flange collar 44 by manipulating trough pan 22 coupled to drain bowl 20. A tight, friction fit between drain bowl body 62 and seepage flange collar 44 is established to maintain upper assembly 14 at a desired position relative to lower assembly 16.

Drain bowl body 62 is positionable within seepage flange collar 44 at a range of positions along central axis 18. In this manner, upper assembly 14 is vertically adjustable along central axis 18 relative to lower assembly 16. Thus, the height of drain 30 and, accordingly, the height of trough pan assembly 10 is adjustable.

To make adjustments to the height of drain 30, and, accordingly, trough assembly 10, drain bowl body 62 is pushed down or pulled up within seepage flange collar 44 along central axis 18. The friction between drain bowl body 62 and seepage flange collar 44 is overcome in order to make these adjustments. As discussed above, this friction is generally sufficient to maintain the position of drain bowl body 62 relative to seepage flange collar 44. In this manner, trough assembly 10 can accommodate variations in height of floor 12 when finished. For example, at a first position, drain bowl rim 60 may be spaced a first distance from seepage flange rim 46 and drain bowl body 62 may extend a first distance past sump drain rim 34 into sump drain 26. At a second position, drain bowl rim 60 may be spaced a second distance from seepage flange rim 46, the second distance being lesser than the first distance drain bowl rim 60 was spaced from seepage flange rim 46 in the first position. Further, drain bowl body 62 may extend a second distance past sump drain rim 34 into sump drain 26, the second distance being greater than the first distance drain bowl body 62 extended past sump drain rim 34 into sump drain body 36 in the first position. That is, the height of drain 30, and, correspondingly, trough assembly 10, is greater in the first position than in the second position.

The angular orientation of upper assembly 14 relative to lower assembly 16 is adjustable. Upper assembly 14 is rotatable relative to lower assembly 16. Drain bowl body 62 may be received by seepage flange collar 44 at any angular orientation. Further, drain bowl body 62 may be rotated within seepage flange collar 44 to any angular orientation once received therein. This avoids the need to provide features for aligning the angular orientation of drain bowl 20 relative to seepage flange 28. This installation method is generally quick and accurate. Further, the need for resetting or reinstalling of trough assembly 10 due to incorrect angular orientation is avoided.

For example, drain bowl body 62 may be positioned in seepage flange collar 44 such that trough pan 22 is at a first angular orientation wherein a first side of trough is substantially parallel to a first wall of the space in which the trough assembly is installed. Drain bowl body 62 may then be rotated within and relative to seepage flange collar 44 by turning trough pan 22 such that the first side of the trough pan is now at a ninety degree angle or perpendicular to the first wall of the space. Trough pan 22 is substantially level with floor 12 or horizontal in its final installed position. Generally, trough is rotated in this level or horizontal orientation.

Drain 30 of trough assembly 10 has a doubled wall design. Drain bowl body 62 forms a passage 120 by extending beyond sump drain rim 34 into the bowl shaped portion of sump drain body 36. Passage 120 provides for travel (i.e., movement, flow, etc.) of fluids entering trough assembly 10 at weep holes 52 within trough assembly 10 through to the plumbing system. In this manner, trough assembly 10 provides for fluids to be gathered and directed to central aperture 32 via both trough pan 22 and weep holes 52.

In some exemplary embodiments, sealant, e.g., a water proof sealant, may be applied to drain bowl body 62 prior to positioning in seepage flange collar 44. The sealant is intended to provide adhesion and prevent flooring material poured during installation from entering trough assembly 10.

Once upper assembly 14 is in the desired position relative to lower assembly 16 (i.e., trough assembly 10 is in the desired position relative to floor 12), a second flooring layer shown as dry grout 122 is poured, although other suitable second flooring layers may be employed. Generally, the second flooring layer is configured to secure trough assembly 10 at the desired position in and relative to floor 12.

In the exemplary embodiment shown, second pour, dry grout 122, is a more permeable material than the material of first pour. Thus, fluids seep into or travel through second pour more quickly than the first pour. In this manner, when fluids seep into floor 12, the fluids travel relatively quickly through second pour toward membrane 110. Membrane 110 guides (directs, etc.) these fluids towards weep holes 52, where the fluids may enter central aperture 32. Thus, the installation of trough assembly 10 provides for fluids to be directed into trough assembly 10 for quick removal. According to other exemplary embodiments, the second pour material may be any of a number of flooring or foundation materials known in the art that are more permeable than the first pour material of slab 100.

Trough assembly 10 may further include anchors shown as anchor straps 124 configured to help secure trough assembly 10 in floor 12. Anchor straps 124 are further configured to help prevent loosening or shifting of trough assembly 10 relative to floor 12 over time. Anchor straps 124 are coupled to the exterior of trough pan 22 at peripheral wall 72 and are set into dry grout 122 extending downward at an angle relative to central axis 18. In the exemplary embodiment shown, anchor straps are shown made of stainless steel, however, a person of skill in the art would recognize that other corrosion-resistant materials may be used.

Trough assembly 10 may further include a strainer 126 configured to prevent large debris from entering and clogging drain 30 of the plumbing system of the structure. Strainer 126 is received in drain bowl 20. In the first embodiment, the strainer is a perforated basket strainer made of stainless steel. However, a person of skill in the art would recognize that the strainer may be of any configuration sufficient to prevent debris from entering and clogging drain 30 and may be made of corrosion resistant materials other than stainless steel.

A finished flooring layer 128 shown as tile and grout is typically installed above the second pour. The finished flooring layer may consist of any material or pattern desired for the space in which the trough assembly is installed. Grate 84 may then be removably positioned on interior ledge 86 of trough pan 22 before use of trough assembly 10.

The installed trough assembly is configured to gather and remove fluids in a space in two primary manners. First, fluids may enter reservoir 24 from at or above finished flooring layer 128. These fluids may fall into reservoir 24 or may run substantially along finished flooring layer 128 into reservoir 24. Fluids entering reservoir 24 pass into central aperture 32 of drain 30 for removal. Second, fluids may enter trough assembly 10 from at or below finished flooring layer 128. Fluids that seeped into floor 12 may enter central aperture 32 through weep holes 52, as described above. Thus, trough assembly 10, as installed, provides for efficient removal of fluids from above and below the finished floor of the space in which it is installed.

In the exemplary embodiment shown, trough pan 22, drain bowl 20, seepage flange 28, and sump drain 26 are made of stainless steel (e.g., 14 gauge stainless steel). Further, all seems are welded, ground, and polished to be water tight. According to other exemplary embodiments, other materials known in the art may be used. Further, other finishing methods known to achieve a water tight assembly may be used.

While drain 30 is shown including a single drain, it should be recognized by those of skill in the art that more than one drain may be used with a single trough pan. Further, multiple trough assemblies may be installed adjacent to one another (e.g., in series, in parallel, or generally in the same space).

In FIG. 5, a second exemplary embodiment of trough assembly 10 is shown including a trough pan 430 and a drain assembly 436. Trough assembly 10 may also include a grate 432, a pair of anchor straps 434, and a strainer 440. Strainer 440 prevents large debris from entering and clogging drain assembly 436 or the plumbing system of the structure. In the exemplary embodiment shown, strainer 440 is a perforated basket strainer made of stainless steel. However, a person of skill in the art would recognize that the strainer may be of any configuration sufficient to prevent debris from entering and clogging drain assembly 436 and may be made of corrosion resistant materials other than stainless steel.

In the second exemplary embodiment, trough pan 430 includes a trough basin 442 having a trough shelf 444 (e.g., ledge, mantle, offset, projection, step, tier, etc.) and a flanged edge 446. The bottom of trough basin 442 includes an opening 450 through which fluids gathered in trough pan 430 exit. While a variety of trough construction methods may be used, trough pan 430 is shown having an all-welded stainless steel construction. However, one of skill in the art would recognize that trough pan 430 may be made of other corrosion-resistant materials. Further, the depth, the length, the width, and the pitch of trough basin 442 may be varied.

Flanged edge 446 includes a plurality of holes (e.g., apertures, openings, etc.) such as grout-locking holes. The grout-locking holes are configured to allow grout to pass through. In this manner, grout-locking holes prevents cracks, which frequently serve as leak points for water. Flanged edge 446 further includes an outer portion 452. Outer portion 452 is a distance below the top surface of floor 12 and covered (e.g., embedded, held down, buried, etc.) beneath the flooring when installed, helping to secure trough pan 430 to within floor 12.

Grate 432 is configured to be received on and supported by trough shelf 444. Grate 432 allows fluids to pass through into trough pan 430 without substantially inhibiting typical uses of floor 12 in which trough assembly 10 is installed. Persons can freely walk on top of the grate 432 and the grate 432 is configured to be non-slip, removable, and anti-fatigue. Grate 432 is depicted made of fiberglass, however, a person of skill in the art would recognize that grate 432 may be made of other suitable materials.

Referring to FIG. 6, drain assembly 436 includes a drain bowl 460, a seepage flange 462, and a sump drain 464. Drain bowl 460 includes a drain bowl rim 480 and a drain bowl body 482. Seepage flange 462 includes seepage flange collar 488, seepage flange rim 490, weep holes 492, and coupling mechanism, shown as stud-receiving holes 494. Sump drain 464 includes a sump drain rim 504, a sump drain body 506, and a plumbing system coupling portion 508. Drain bowl 460, seepage flange 462, and sump drain 464 are shown made of stainless steel, however, any corrosion resistant material may be used.

Referring back to FIG. 5, drain assembly 436 preferably has a double wall design. When assembled, drain bowl 460, seepage flange 462, and sump drain 464 define a central aperture 466 of drain assembly 436. Fluids entering trough assembly 10 from at or above floor 12 flow in through trough pan 430 into central aperture 466 and are removed by the plumbing system. Fluids entering trough assembly 10 from at or below floor 12 pass through weep holes 492 flow into central aperture 466 and are removed by the plumbing system. According to the exemplary embodiment shown, central aperture 466 is substantially vertical and drain bowl 460, seepage flange 462, sump drain 464, and central aperture 466 are substantially aligned along a central axis 468.

Referring to FIGS. 6-7, drain bowl rim 480 extends radially outward from the top of drain bowl body 482, forming the inlet to central aperture 466 for fluids entering drain assembly 436. Drain bowl body 482 includes an upper opening 484 (e.g., aperture, hole, etc.) substantially opposite drain bowl rim 480. Upper opening 484 enables fluids entering at the inlet to central aperture 466 of drain assembly 436 to exit drain bowl 460 and continue through central aperture 466 (see, e.g., FIG. 5 illustrating central aperture 466).

A plurality of coupling protrusions, shown as weld studs 486, are located around the perimeter of drain bowl body 482. Weld studs 486 are welded to drain bowl body 482, ensuring that drain bowl body 482 has a watertight exterior and preventing fluids in drain bowl 460 from leaking out of drain assembly 436 into floor 12. Seepage flange collar 488 includes slots 500. Slots 500 are configured to cooperate with weld studs 486 of drain bowl 460. The cooperation of weld studs 486 and slots 500 allows for adjustability of drain assembly 436.

Weld studs 486 and slots 500 provide for vertical adjustability of drain bowl 460 relative to seepage 462 along central axis 468. Weld studs 486 and slots 500 are correspondingly spaced on drain bowl 460 and seepage flange 462, respectively. Slots 500 are open-ended, beginning at the top edge of seepage flange collar 488 and extending downward. In the exemplary embodiment shown, slots 500 are shown extending substantially vertically downward into seepage flange collar 488. In other exemplary embodiments, the slots may be configured in any manner sufficient to provide for vertical adjustability of the drain assembly. For example, slots 500 may be wider to accommodate weld studs having a larger diameter.

To couple drain bowl 460 and seepage flange 462, weld studs 486 are moved down through the open-ended side of slots 500 and received therein. Weld studs 486 of drain bowl 460 may be positioned in slots 500 of seepage flange 462 by manipulating trough basin 442, which is coupled to drain bowl 460 before assembly and installation. In the exemplary embodiment shown, trough basin 442 is welded to drain assembly 436 about drain bowl rim 480, creating a watertight coupling of trough pan 430 and drain assembly 436.

Weld studs 486 are secured in slots 500 using coupling mechanisms, shown as nuts 502. Weld studs 486 can be secured in a range of locations along slots 500, providing for adjustments to the vertical position of drain bowl 460 relative to seepage flange 462 and sump drain 464. Once coupled, seepage flange collar 488 in-part encircles drain bowl 460. In this manner, seepage flange collar 488 has the advantage of helping stabilize drain assembly 436. According to some exemplary embodiments, the drain bowl may have a friction fit with the seepage flange collar, further securing the drain bowl, and, accordingly, the trough pan, relative to the seepage flange.

The height of the drain bowl 460 relative to the seepage flange rim 490 may be varied in order to accommodate varying floor heights, thus, further providing for the adjustability of the height of drain assembly 436 along central axis 468. Referring to FIG. 6, the seepage flange collar is shown having a first height. Referring to FIG. 8, the seepage flange collar is shown having a second height. The first height of the seepage flange collar shown in FIG. 6 is greater than the second height of the seepage flange collar shown in FIG. 8. Accordingly, all else equal, drain assembly 436 extends a greater length vertically along central axis 468 in FIG. 5 than in FIG. 9. Further, drain bowl 460 does not extend as far down into sump drain 464 in FIG. 5 as it does in FIG. 9. In fact, drain bowl 460 may not extend into sump drain 464 at all in FIG. 5. This adjustability allows for accommodation of construction variations, including, but not limited to, variations in the elevation of the finished floor elevation. It should be noted that drain bowl 460 does not extend so far into sump drain 464 that drain bowl 460 contacts sump drain body 506, providing clearance between drain bowl 460 and sump drain body 506 through which fluids may travel.

Further referring to FIG. 5-7, seepage flange rim 490 extends substantially radially outward from the bottom of seepage flange collar 488. In the exemplary embodiment shown, seepage flange rim 490 includes a first portion 496 and a second portion 498. First portion 496 of seepage flange rim 490 is at an angle to central axis 468 and is located substantially between the bottom of seepage flange collar 488 and second portion 498 of seepage flange rim 490. Second portion 498 is substantially perpendicular to central axis 468. In one exemplary embodiment, both the first portion and the second portion are substantially perpendicular to the central axis.

Referring back to FIGS. 6-7, sump drain rim 504 extends radially outward from the top of sump drain body 506. Sump drain body 506 is substantially bowl shaped, being wider at the top than at the bottom and having an aperture at both the top and the bottom. Plumbing system coupling portion 508 is at the distal end of drain assembly 436, extending downward from the aperture at the bottom of sump drain body 506. At the bottom of drain assembly 436, plumbing system coupling portion 508 is adapted to be coupled to the plumbing system. Fluids collected by trough assembly 10 eventually exit through plumbing system coupling portion 508 to the plumbing system.

According to one exemplary embodiment, sump drain 464 further includes a coupling mechanism, shown as studs 510 which extend substantially vertically upwards from the top of sump drain rim 504. Ideally, the studs 510 are welded to the sump drain rim 504 which maintains the water impervious nature of the rim 504. The studs 510 correspond with stud-receiving holes 494 provided on second portion 498 of seepage flange rim 490, enabling seepage flange 462 to be coupled to sump drain 464. Stud-receiving holes 494 of seepage flange 462 receive studs 510 of sump drain 464. Coupling mechanisms shown as nuts 512 are threaded onto the studs 510 in order to secure the seepage flange 462 to the sump drain 464. When studs 510 and stud-receiving holes 494 are substantially aligned, seepage flange 462 and sump drain 464 are also substantially aligned along central axis 468, seepage flange 462 being above sump drain 464.

Referring back to FIG. 5, any fluids entering through weep holes 492 directly enter central aperture 466 of drain assembly 436. Fluids entering drain assembly 436 through weep holes 492 will not be obstructed by drain bowl 460 because there is a clearance 514 between drain bowl 460 and an upper opening 516 of sump drain 464. This configuration allows weep holes 492 to be positioned close to central axis 468. In the exemplary embodiment shown, weep holes 492 are located on seepage flange rim 490 substantially above upper opening 516 of sump drain 464.

Further referring to FIG. 5, trough assembly 10 is embedded in floor 12. In the first embodiment, floor 12 includes a finished portion, shown as tile and grout 536, and an unfinished portion including a first pour or slab 530, shown as concrete, and a second pour, shown as dry grout 532. The second pour is generally above the first pour.

Sump drain 464 is received in slab 530 such sump drain rim 504 is substantially flush with the top of slab 530. In one exemplary embodiment, sump drain 464 is received in a cavity in slab 530 In another exemplary embodiment, sump drain 464 is embedded in slab 530. In still another exemplary embodiment, a recess may be formed surrounding the cavity to receive the sump drain rim.

A membrane, shown as waterproof membrane 438, may extend over the top of slab 530 and sump drain rim 504, creating a barrier that inhibits fluids that have seeped into floor 12 from leaking through floor 12 to spaces below. According to one exemplary embodiment, waterproof membrane 438 (e.g., Bituthene 3000) utilizes an adhesive and primer to secure it to slab 530 (e.g., Bituthene WP-3000, and Bituthene Primer B2). A hole 534 in waterproof membrane 438 substantially corresponds to the opening defined by sump drain rim 504 of sump drain 464, preventing waterproof membrane 438 from inhibiting the movement of fluids in central aperture 466. The hole may be pre-cut or cut during installation.

When seepage flange 462 is coupled to sump drain 464 at sump drain rim 504, the waterproof membrane 438 is pinched between seepage flange rim 490 and sump drain rim 504. Sump drain rim 504 is holeless, avoiding the potential for any fluids to leak below waterproof membrane 438.

Trough pan 430 is located substantially above drain assembly 436. According to one exemplary embodiment, the second pour covers waterproof membrane 438 and builds up around the exterior of seepage flange 462, drain bowl 460, and trough pan 430, and the second pour extends up to flanged edge 446. Flanged edge 446 is embedded in the second pour. Further, anchor straps 434 are embedded in the second pour to help secure trough pan 430 in floor 12. Anchor straps 434 are coupled to the exterior of trough basin 442 and are set into the second pour at an angle to trough basin 442. Anchor straps 434 are shown made of stainless steel, however, a person of skill in the art would recognize that other corrosion-resistant materials may be used. The finished portion, tile and grout 536, of floor 12 is installed on top of the second pour, extending over the outermost portion of flanged edge 446.

The second pour is more permeable than the first pour, allowing fluids to seep through more quickly. When fluids seep into floor 12, the material of the second pour allows the fluids to efficiently move down toward waterproof membrane 438. Fluids that seep into floor 12 eventually encounter waterproof membrane 438. Waterproof membrane 438 directs seepage fluids towards weep holes 492 of drain assembly 436.

Weep holes 492 provide a means for properly draining seepage fluid. Weep holes 492 define a passage between the exterior and interior of drain assembly 436: Fluid which has entered the floor 12 can flow through weep holes 492 into central aperture 466 of drain assembly 436 for conventional removal rather than pass through the trough pan. The location of sump drain 464 below seepage flange 462 allows any fluids entering through weep holes 492 to flow directly into central aperture 466 of drain assembly 436.

Fluids gathered in trough pan 430 enter drain assembly 436 at the inlet defined by drain bowl rim 480. Fluids gathered in trough pan 430 and fluids entering through weep holes 492 comingle in central aperture 466, exiting through the waste pipe.

Trough assembly 10 can also be configured to utilize multiple drain assemblies 436. It should also be noted that the basic dimensions of trough pan 430 may be varied depending on the restrictions of the space or the needs of those using the space.

As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

It should be noted that the term “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

It is also important to note that the construction and arrangement of the trough assembly as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, coupling arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present inventions.

Claims

1. A floor trough assembly, comprising:

an upper assembly including a drain bowl and a trough coupled to the drain bowl;

a lower assembly adapted to be mounted vertically below the upper assembly, the lower assembly comprising a seepage flange having a collar configured to receive the drain bowl, wherein the upper assembly is adjustable relative to the lower assembly by positioning the drain bowl in the seepage flange, the drain bowl being moveable therein.

2. A floor trough assembly according to claim 1 wherein the drain bowl is adjustable vertically with respect to the seepage flange.

3. A floor trough assembly according to claim 1 wherein the drain bowl is rotationally adjustable relative to the seepage flange about a substantially vertical axis.

4. A drain assembly, comprising:

a sump drain having a sump drain rim and an upper opening; and

a seepage flange, a collar and a seepage flange rim extending substantially radially outward from the bottom of the collar, wherein the seepage flange rim is coupled to the sump drain rim and includes at least one weep hole, the weep hole being located substantially above the upper opening of the sump drain; and

a membrane secured between the sump drain rim and the seepage flange rim, the membrane configure to guide fluids into the weep holes.

5. A floor trough assembly installation, comprising:

a drain;

a first pour comprising a first material;

a second pour substantially above the first pour comprising a second material; and a membrane positioned between the first pour and the second pour, the membrane configured to prevent fluids from seeping into the first pour and to guide fluids into the drain.