CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 61/802,048, filed Mar. 15, 2013, and U.S. Provisional Application No. 61/878,248, filed Sep. 16, 2013.
BACKGROUND The invention relates generally to a system configured to facilitate drainage from the floor of a screened porch, lanai, pool cage, or other screened enclosure.
Property owners often enclose a porch, lanai, pool, or other area with mesh screen for protection against insects and/or other pests. Screened enclosures can collect rain water. In addition, water might also collect on the floor of an enclosure from a pool, fountain, or other water feature within the enclosure. Conventional screen framing can trap such water inside the enclosure, which can lead to unhealthy and unsightly mold growth.
Many times, property owners do not anticipate installing a screened enclosure. Accordingly, drainage provisions may not exist, for instance, in the original slab of a porch or patio. Moreover, it may be cost prohibitive to add a trench or other drainage system to a pre-existing concrete slab. For these and other reasons, an inexpensive and effective system is needed to facilitate drainage from the floor of a screened enclosure.
SUMMARY OF THE INVENTION Embodiments of the invention solve one or more of the shortcomings described above by modifying a floor member of a screened enclosure wall frame to include at least one drainage channel. The drainage channel facilitates drainage (typically of water from inside the screened enclosure to outside the screened enclosure), while also providing a barrier to insects and other pests. In a first embodiment, the drainage channel includes gate openings and corresponding gates disposed directly onto each side of a floor member of a screen frame. A variant of the first embodiment includes a weeping slot on at least one side of the drainage channel. In second and third embodiments, a section of the floor member is replaced with a drain insert. A drainage channel in the drain insert may include one or more gate openings and associated gates. The drainage channel in the drain insert may also include one or more weeping slots. In variants of the second or third embodiments, the body of the drain insert is configured as a two-part assembly to facilitate the plastic molding of one or more spline grooves in the drain insert.
BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the invention are described with reference to the following drawings, wherein:
FIG. 1 is a perspective view of a screened enclosure;
FIG. 2 is a perspective view of a floor member;
FIG. 3 is perspective view of a vertical or horizontal frame member;
FIG. 4 is a perspective view of a floor member;
FIG. 5 is an exploded assembly view of a drainage system according to a first embodiment of the invention;
FIG. 6 is a perspective view of an installed drainage system according to the first embodiment of the invention with a gate in a closed position;
FIG. 7 is a perspective view of an installed drainage system according to the first embodiment of the invention with gates in an open position;
FIG. 8 is a perspective view of a floor member;
FIG. 9A is a first exploded assembly view of a drainage system according to a second embodiment of the invention;
FIG. 9B is a perspective view for a detail of the drain insert in FIG. 9A according to a variation of the second embodiment of the invention;
FIG. 10 is a second exploded assembly view of a drainage system according to the second embodiment of the invention;
FIG. 11 is a perspective view of an installed drainage system according to the second embodiment of the invention;
FIG. 12 is a perspective view of a floor member;
FIG. 13 is an exploded assembly view of a drainage system according to a third embodiment of the invention;
FIG. 14 is a perspective view of an installed drainage system according to the third embodiment of the invention;
FIG. 15A is an elevation view of a first gate;
FIG. 15B is an elevation view of a variation of the first gate;
FIG. 15C is an elevation view of a variation of the first gate;
FIG. 15D is an end view for the variations of the first gate illustrated in FIGS. 15B and 15C;
FIG. 16 is an elevation view of a second gate;
FIG. 17 is an elevation view of a third gate;
FIG. 18 is an elevation view of a fourth gate;
FIG. 19 is a perspective view of an installed drainage system according to a variant of the first embodiment of the invention;
FIG. 20 is a perspective view of an installed drainage system according to a variant of the second embodiment of the invention;
FIG. 21 is a perspective view of an installed drainage system according to a variant of the third embodiment of the invention;
FIG. 22 is a perspective view of an installed drainage system according to a variant of the second embodiment of the invention;
FIG. 23 is a perspective view of an installed drainage system according to a variant of the third embodiment of the invention;
FIG. 24A is an exploded assembly sectional view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 24B is an sectional view of a drain insert according to the variant of the third embodiment of the invention illustrated in FIG. 24A;
FIG. 25A is an exploded assembly sectional view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 25B is an sectional view of a drain insert according to the variant of the third embodiment of the invention illustrated in FIG. 25A;
FIG. 26A is an exploded assembly sectional view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 26B is an sectional view of a drain insert according to the variant of the third embodiment of the invention illustrated in FIG. 26A;
FIG. 27A is an exploded assembly sectional view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 27B is an sectional view of a drain insert according to the variant of the third embodiment of the invention illustrated in FIG. 27A;
FIG. 28A is a side view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 28B is a side view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 28C is a side view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 28D is a side view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 29 is an exploded end view of a drain insert according to a variant of the third embodiment of the invention;
FIG. 30 is an end view of the drain insert in FIG. 29 according to a variant of the third embodiment of the invention;
FIG. 31 is a sectional view of the drain insert in FIG. 29 according to a variant of the third embodiment of the invention;
FIG. 32 is a top view of the drain insert in FIG. 29 according to a variant of the third embodiment of the invention;
FIG. 33 is a top view of the drain insert in FIG. 29 with gates installed according to a variant of the third embodiment of the invention;
FIG. 34 is a side view of the drain insert in FIG. 29 according to a variant of the third embodiment of the invention; and
FIG. 35 is a side view of the drain insert in FIG. 29 with a gate installed according to a variant of the third embodiment of the invention.
DETAILED DESCRIPTION In the drawings, features may not be rendered in true scale or proportion. In addition, certain features may be omitted in some views for clarity. The headings used in this section of the specification are for organizational convenience only and do not necessarily restrict the disclosure of any particular feature to any particular sub-section.
Screened Enclosures FIG. 1 is a perspective view of a screened enclosure. In the illustrated view, a screened enclosure 110 is coupled to a building 105. The screened enclosure 110 may be, for example, a screened room, a lanai, a pool cage or other enclosure. The building 105 may be, for instance, a residential house. As shown in FIG. 1, the screened enclosure includes a frame having floor members 115, vertical members 120, and horizontal members 125. These frame components support the screen 130.
FIG. 2 is a perspective view of a floor member 115. In the illustrated example, the floor member 115 has an open bottom 205, a screen side 210 and a non-screen side 220. The screen side 210 includes a spline groove 215. The spline groove 215 cooperates with spline (cord), not shown, to secure the screen 130 as will be appreciated by persons skilled in the art of screening. The cross-section of a floor member 115 typically measures 1″×2″, or 1″×3″, but the invention is not limited to such dimensions.
FIG. 3 is perspective view of a vertical member 120 or a horizontal member 125. In the illustrated example, the vertical/horizontal member 120/125 includes a first spline groove 305 and a second spline groove 310 on the same (screen) side of the vertical/horizontal member 120/125. The spline grooves 305 and 310 cooperate with spline (cord), not shown, to secure the screen 130 as will be appreciated by persons skilled in the art of screening. The cross-section of a vertical member 120 or horizontal member 125 may be, for example, 2″×2″, 2″×3″, 2″×4″, 2″×5″, 2″×6″, or 3″×3″, but the invention is not limited to such dimensions.
The floor members 115, vertical members 120, and horizontal members 125 described above with reference to FIGS. 1-3 may be, for instance, aluminum extrusions. Other materials and manufacturing methods are also possible, however, and the invention is not limited to cooperation or combination with extruded aluminum components. For example, alternative metals or plastics could be used.
Each of the three drainage system embodiments described below relate to one or more portions of the floor member 115.
First Drainage System Embodiment A first embodiment of the invention and variants thereof are described below with reference to FIGS. 4-7, 15-18, and 19. The first embodiment and its variants are modified floor members 115.
FIG. 4 is a perspective view of a floor member 115 prior to modification. FIG. 5 is an exploded assembly view of a drainage system according to a first embodiment of the invention. As illustrated in FIG. 5, a gate 505 is configured to cover a gate opening 510 in the floor member 115. Advantageously, the gate opening 510 has no floor, which would impede fluid flow. A first fastener 515 cooperates with a pivot hole 520 in the gate 505 and is affixed to the floor member 115 at the pilot hole 525. A second fastener 530 cooperates with a slot 535 in the gate 505 and is affixed to the floor member 115 at the pilot hole 540. The fasteners 515 and 530 may be screws, as shown. Stand-off washer 545 is optional, but preferable.
FIG. 6 is a perspective view of an installed drainage system according to the first embodiment of the invention with the gate 505 in a closed position. Although not shown in FIGS. 5 and 6, the floor member 115 is also configured with an identical gate opening 510, gate 505, and related hardware, on the opposite (screen) side. The two gates 505 are in alignment to create a drainage channel through the floor member 115. FIG. 7 shows a gate 505 pair in an open position. FIG. 7 also illustrates that the gate 505 is configured to pivot about the fastener 515 to expose the gate opening 510. The slot 535 in the gate 505 permits the release of one end of the gate 505 from the floor member 115 while leaving the fastener 530 affixed to the floor member 115. With proper tension on the fasteners 515 and 530, such pivoting can be easily accomplished manually without operating on the fasteners 515 and 530.
The spline groove 215 is not illustrated in FIGS. 4-7. The spline groove 215 exists on the screen side of the floor member 115, however, and the gate opening 510 and related gate hardware on the screen side may be disposed below the spline groove 215 to avoid interference with the function of the spline groove 215.
The gate pair described above with reference to FIGS. 5-7 could be repeated multiple times in the floor member 115 of a screened enclosure to create multiple drainage channels.
In use, the gates 505 are preferably configured to facilitate drainage through a drainage channel even when the gates 505 are in a closed position (see discussion regarding gate floor apertures 1510 and 1710 with reference to FIGS. 15-17). For higher volume fluid flow, for instance when cleaning the interior floor of a screened enclosure with a hose, the gates 505 can be opened as illustrated in FIG. 7.
Second Drainage System Embodiment A second embodiment of the invention and variants thereof are described below with reference to FIGS. 8-11, 15-18, 20, and 22. The second embodiment and its variants are described herein as drain inserts.
FIG. 8 is a perspective view of a floor member 115 prior to modification. FIG. 9A is a first exploded assembly view of a drainage system according to a second embodiment of the invention. With reference to FIGS. 8 and 9A, it can be seen that a section of the floor member 115 has been removed. Accordingly, the floor member 115 is modified to include a first portion of the floor member 905 (having a pilot hole 910) and a second portion of the floor member 915 (having a pilot hole 920). As also shown, a drain insert 925 includes pilot holes 930 and 935, and a first gate 505 that obscures a first gate opening 510.
The drain insert 925 also includes a second gate opening 510 and a second gate 505 (not visible in FIG. 9) on a screen side of the drain insert 925. The second gate opening 510, second gate 505, first gate opening 510, and first gate 505 cooperate to form a drainage channel through the drain insert 925. The screen side of the drain insert 925 also includes a spline groove 215 (not shown). The second gate opening 510 and hardware associated with the second gate 505 preferably are disposed below the spline groove 215 to avoid interference with the function of the spline groove 215.
The drain insert 925 could be constructed of aluminum, plastic, or other suitable material or combination of materials. In use, the drain insert 925 is disposed between the first portion of the floor member 905 and the second portion of the floor member 915. Additional features for securing the drain insert 925 to the first floor member 905 and the second floor member 915 will be described below with reference to FIGS. 10 and 11.
The gate 505 can be secured to the drain insert 925 using optional washer 545 and fasteners 515 and 530 as described with reference to the embodiment in FIG. 5. Alternatively, the drain insert 925 could include a standoff 940 and split pin 945 to retain the pivoting side of the gate 505. The drain insert could also include a standoff 950 and post 955 (with a head 960) to retain the slotted side of the gate 505 as illustrated in FIG. 9B. Preferably, the standoffs 940 and 950, split shaft 945, and post 955 are fabricated as an integral part of the drain insert 925. The gate attachment features illustrated in FIG. 9B could be used with any of the drain insert embodiments or variants described herein.
FIG. 10 is a second exploded assembly view of a drainage system according to the second embodiment of the invention. FIG. 10 shows that joiner hardware 1005 secures the drain insert 925 to the first portion of the floor member 905 using fasteners 1010. Likewise, joiner hardware 1015 secures the drain insert 925 to the second portion of the floor member 915 using fasteners 1020. FIG. 11 is a perspective view of an installed drainage system according to the second embodiment of the invention. The joiner hardware 1005 and 1015 is disposed on a top and non-screen side of the drain insert 925 to avoid interference with the spline groove 215 (not shown).
Variations to the second embodiment described above are possible. For instance, four fasteners could be disposed in each joiner hardware 1005 and 1015 instead of the two fasteners each illustrated in FIGS. 10 and 11.
Multiple drain inserts 925, described above with reference to FIGS. 9-11, could be disposed in the floor member 115 of a screened enclosure.
Once installed, the drainage system of the second embodiment functions as described above with reference to the first embodiment. The second embodiment may be advantageous in instances such as high-rise balconies where access to the outside of the screen enclosure (for cutting a gate hole 510 in the floor member 115 and installing the gate 505) is not practical. In such cases, the screen side of the floor member 115 and drain insert 925 may be disposed facing the inside of the screened enclosure to facilitate screening and/or rescreening.
Third Drainage System Embodiment A third embodiment of the invention and variants thereof are described below with reference to FIGS. 12-18, 21, 23, 24A, 24B, 25A, 25B, 26A, 26B, 27A, 27B, 28A-D, and 29-35. The third embodiment and its variants are also referred to as drain inserts in this specification.
FIG. 12 is a perspective view of a floor member prior to modification. FIG. 13 is an exploded assembly view of a drainage system according to a third embodiment of the invention. With reference to FIGS. 12 and 13, it can be seen that a section of the floor member 115 has been removed. Accordingly, the floor member 115 is modified to include a first portion of the floor member 1305 (having a pilot hole 1310) and a second portion of the floor member 1315 (having a pilot hole 1320). As also shown, a drain insert 1325 includes a pilot hole 1330 on a first tongue portion 1335, a pilot hole 1340 on a second tongue portion 1345, and a first gate 505 concealing a first gate opening 510. The gate 505 may be assembled as described above with reference to the first embodiment and FIG. 5.
The drain insert 1325 also includes a second gate opening 510 and a second gate 505 (not visible in FIG. 13) on a screen side of the drain insert 1325. The second gate opening 510, second gate 505, the first gate opening 510, and first gate 505 cooperate to form a drainage channel through the drain insert 1325. The screen side of the drain insert 1325 also includes a spline groove 215 (not shown). The second gate opening 510 and hardware related to the second gate 505 preferably are disposed below the spline groove 215 to avoid interference with the function of the spline groove 215.
The drain insert 1325 could be constructed of aluminum, plastic, or other suitable material or combination of materials. In use, the drain insert 1325 is disposed between the first portion of the floor member 1305 and the second portion of the floor member 1315 using fasteners 1350 and 1355 as illustrated in FIG. 13.
FIG. 14 is a perspective view of an installed drainage system according to the third embodiment of the invention. Multiple drain inserts 1325, described above with reference to FIGS. 13 and 14, could be disposed in the floor member 115 of a screened enclosure. Once installed, the drainage system of the third embodiment functions as described above with reference to the first embodiment. Like the second embodiment, the third embodiment may also be advantageous in instances such as high-rise balconies where access to the outside of the screen enclosure (for cutting a gate hole 510 in the floor member 115 and installing the gate 505) is not practical. In such cases, the screen side of the floor member 115 and drain insert 1325 may be disposed facing the inside of the screened enclosure to facilitate screening and/or rescreening.
Alternative Gates The gate 505 alternatives described below with reference to FIGS. 15A-18 are applicable to any embodiments of the invention that include at least one gate. But the invention is not limited to the disclosed gate alternatives. Other gate 505 variants could be used.
FIG. 15A is an elevation view of a gate alternative. As illustrated in FIG. 15A, the gate 505 includes a pivot hole 520 and slot 535 as described above with reference to FIG. 5. In addition, the gate 505 includes a sloped pivot end 1505. This sloped pivot end 1505 allows the gate 505 to pivot without interfering with a floor of a screened enclosure, as can be seen with reference to FIG. 7. Gate floor apertures 1510 permit drainage through a drainage channel even when the gate 505 is disposed on the floor member 115, gate insert 925, or gate insert 1325 in a closed position. FIG. 15 also shows that a slot end 1515 of the gate 505 may be sloped or squared off, according to design choice.
FIG. 15B illustrates a first variant of the gate 505 illustrated in FIG. 15A, and FIG. 15C illustrates a second variant of the gate 505 in FIG. 15A. In particular, the variants in FIGS. 15B and 15C include a lip 575 that preferably extends the full length of the gate 505 (as shown). In one respect, the lip 575 improves the rigidity of the gate 505. In another respect, the lip 575 facilitates manual opening and closing of the gate 505 when in use. FIGS. 15B and 15C illustrate that the lip 575 is preferably disposed on one side or the other side of the gate 505, but not on both sides of the gate 505. FIG. 15D illustrates an end view of the gate 505 for the variants discussed above with reference to FIGS. 15B and 15C. A similar lip could be included on any gate, including (but not limited to) those described below with reference to FIGS. 16-18.
FIG. 16 is an elevation view of a second gate. In addition to the features described above with reference to FIG. 15A, the gate 505 in FIG. 16 also includes gate body apertures 1605, which may improve drainage when the gate is disposed in a closed position and a deeper accumulation of water is being drained through a drainage channel.
FIG. 17 is an elevation view of a third gate. In the illustrated alternative, the rounded gate floor apertures 1510 are replaced with squared floor apertures 1705. Likewise, the gate body apertures 1605 are replaced by the body apertures 1710.
FIG. 18 is an elevation view of a fourth gate. In the illustrated alternative, the gate 505 includes a single elongated drainage aperture 1805 disposed along a bottom edge of the gate 505.
The minimum feature size for the gate apertures 1510, 1605, 1705, 1710, and 1805 is preferably less than ½″ to effectively block mice, snakes, scorpions and other pests while still allowing drainage when the gate 505 is disposed in a closed position.
Other gate configurations are also possible. For example, a variant of the gate 505 could include two slots 535 instead of a pivot hole 520 and single slot 535. In this instance, a second slot 535 would essentially replace the pivot hole 520. A gate 505 with two slots 535 could be affixed to floor member 115 or any of the drain inserts disclosed herein, for instance, using two fasteners 530 (each fastener 530 cooperating with a corresponding one of the slots 535). Alternatively, each of the slots 535 could be configured to cooperate with a post (such as the post 555 or 2970 disclosed with reference to FIGS. 9B and 31); in this instance, a post 555, 2970 would replace the split shaft 945, 2965.
Weeping Slots As used herein, a weeping slot is a type of drainage opening at one end of a drainage channel in a floor member or drain insert. Like the gate opening 510, a weeping slot does not include a floor, which would impede fluid flow. A weeping slot is distinguished from a gate opening in that a weeping slot is not configured for use with a gate 505. A first type of weeping slot is illustrated in FIGS. 19-21; a second type of weeping slot is illustrated in FIGS. 22 and 23.
In FIGS. 19-21, a weeping slot 1905 is preferably disposed on a side opposite a gate opening 510 (not shown) and gate 505 to form a drainage channel in the corresponding floor member 115 or drain insert 925, 1325. The weeping slot 1905 may be lower in height than a gate opening 510 and is preferably no taller than about ½″ as measured from the bottom of the floor member to effectively block mice, snakes, scorpions and other pests while still allowing drainage through the floor member or drain insert. Variations to the configurations illustrated in FIGS. 19-21 are possible. For instance, the weeping slot 1905 could be disposed on a screen side, a non-screen side, or both sides of a floor member 115 or drain insert 925, 1325, according to application needs.
FIG. 22 illustrates a second type of weeping slot 2210 that is applied to insert 925. The weeping slot 2210 is preferably disposed on a side opposite a gate opening 510 (not shown) and gate 505 to form a drainage channel through the drain insert 925. As shown, the weeping slot 2210 extends the full length of a side wall of the insert 925. When installed, the weeping slot 2210 extends to a height 2215 from a slab or other surface to which floor member portions 905 and 915 are mounted. The weeping slot 2210 could be disposed on a screen side, a non-screen side, or both sides of the drain insert 925.
Likewise, with reference to FIG. 23, it can be seen that weeping slot 2310 extends the full length of a side wall of the insert 1325. The weeping slot 2310 is preferably disposed on a side opposite a gate opening 510 (not shown) and gate 505 to form a drainage channel through the drain insert 1325. When installed, the weeping slot 2310 extends to a height 2315 from a slab or other surface to which floor member portions 1305 and 1315 are mounted. The weeping slot 2310 could be disposed on a screen side, a non-screen side, or both sides of the drain insert 1325.
The application of a weeping slot 1905, 2210 or 2310 in a floor member 115 or drain insert may be advantageous, for instance, on the outside of a screened enclosure when access to outside surfaces of the screened enclosure is limited (making the use of a gate 505 impractical). One or more weeping slots 1905, 2210, 2310 may be included with any drainage system embodiment disclosed herein.
Two-Piece Drain Inserts Due to economic considerations, it may be desirable to manufacture a drain insert (for example drain insert 925 or 1325) using plastic mold fabrication processes. Including a spline groove 215 in a body of a drain insert presents mold release challenges, however. To solve this problem, a drain insert can be fabricated in two molded pieces where each piece includes a spline channel. As used herein, a spline channel is a portion of a spline groove. A single spline channel, by itself, could not retain a spline (cord). A spline groove can retain a spline. FIGS. 24A&B, 25A&B, 26A&B, 27A&B are sectional views illustrating two-piece drain insert variants of the third embodiment of the invention. FIGS. 28A-D each present an exemplary side view for a completed two-piece drain insert assembly. Another two-piece variant of the third embodiment is described with reference to FIGS. 29-35.
According to a first two-piece variant illustrated in FIGS. 24A&B, a top piece 2405 is configured to couple to a bottom piece 2410. The top piece 2405 includes a top spline channel 2415, and ridges 2420. The ridges 2420 preferably extend the full length of the top piece 2405. The bottom piece 2410 includes a drainage channel 2400, a bottom spline channel 2430 and slots 2435. The slots 2435 preferably extend the full length of the bottom piece 2410 and are configured to cooperate with the ridges 2420. An adhesive may be used to join the top piece 2405 to the bottom piece 2410. Alternatively, sonic welding or another joining process could be used to join the top piece 2405 to the bottom piece 2410. FIG. 24B illustrates that, once assembled, the top spline channel 2415 and the bottom spline channel 2430 form a spline groove 2440 in the two-piece insert.
The drainage channel 2400 could be configured to cooperate with one or more gates 505. In an alternative variant (not illustrated), the top piece 2405 and bottom piece 2410 could be configured to form a second spline groove 2440 on the opposite side of the two-piece insert from the illustrated spline groove 2440.
According to a second two-piece variant illustrated in FIGS. 25A&B, a top piece 2505 is configured to couple to a bottom piece 2510. The top piece 2505 includes a top spline channel 2515, ridges 2520, and cavity 2545. The ridges 2520 preferably extend the full length of the top piece 2505. The cavity 2545 advantageously reduces the amount of material required to fabricate the top piece 2505. The bottom piece 2510 includes a drainage channel 2500, bottom spline channel 2530 and slots 2535. The slots 2535 preferably extend the full length of the bottom piece 2510 and are configured to cooperate with the ridges 2520. An adhesive may be used to join the top piece 2505 to the bottom piece 2510. Alternatively, sonic welding or another joining process could be used to join the top piece 2505 to the bottom piece 2510. FIG. 25B illustrates that, once assembled, the top spline channel 2515 and the bottom spline channel 2530 form a spline groove 2540 in the two-piece insert.
The drainage channel 2500 could be configured to cooperate with one or more gates 505. In an alternative variant (not illustrated), the top piece 2505 and bottom piece 2510 could be configured to form a second spline groove 2540 on the opposite side of the two-piece insert from the illustrated spline groove 2540.
According to a third two-piece variant illustrated in FIGS. 26A&B, a top piece 2605 is configured to couple to a bottom piece 2610. The top piece 2605 includes a top spline channel 2615, ridges 2620, and cavity 2645. The ridges 2620 preferably extend the full length of the top piece 2605. The cavity 2645 advantageously reduces the amount of material required to fabricate the top piece 2605. The bottom piece 2610 includes a drainage channel 2600, a bottom spline channel 2630, slots 2635, and cavity 2650. The slots 2635 preferably extend the full length of the bottom piece 2610 and are configured to cooperate with the ridges 2620. The cavity 2650 advantageously reduces the amount of material required to fabricate the bottom piece 2610. An adhesive may be used to join the top piece 2605 to the bottom piece 2610. Alternatively, sonic welding or another joining process could be used to join the top piece 2605 to the bottom piece 2610. FIG. 26B illustrates that, once assembled, the top spline channel 2615 and the bottom spline channel 2630 form a spline groove 2640 in the two-piece insert.
The drainage channel 2600 may be configured to cooperate with one or more gates 505. In an alternative variant (not illustrated), the top piece 2605 and bottom piece 2610 could be configured to form a second spline groove 2640 on the opposite side of the two-piece insert from the illustrated spline groove 2640. The cavity 2645 could be closed at one or both ends of the top piece 2605. Likewise, the cavity 2650 could be closed at one or both ends of the bottom piece 2605.
According to a fourth two-piece variant illustrated in FIGS. 27A&B, a top piece 2705 is configured to couple to a bottom piece 2710. The top piece 2705 includes a top spline channel 2715, ridges 2720, and cavity 2745. The ridges 2720 preferably extend the full length of the top piece 2705. The cavity 2745 advantageously reduces the amount of material required to fabricate the top piece 2705. The bottom piece 2710 includes gate openings 2700, a bottom spline channel 2730, slots 2735, and cavity 2750. Each of the gate openings 2700 is preferably configured to cooperate with a corresponding gate 505. The slots 2735 preferably extend the full length of the bottom piece 2710 and are configured to cooperate with the ridges 2720. The cavity 2750 advantageously reduces the amount of material required to fabricate the bottom piece 2710. An adhesive may be used to join the top piece 2705 to the bottom piece 2710. Alternatively, sonic welding or another joining process could be used to join the top piece 2705 to the bottom piece 2710. FIG. 27B illustrates that, once assembled, the top spline channel 2715 and the bottom spline channel 2730 form a spline groove 2740 in the two-piece insert.
As indicated by optional feature 2755, one or more weeping slots could be substituted for a corresponding one or more of the gate openings 2700. Such weeping slot(s) could extend a partial length or a full length of the drain insert. In an alternative variant (not illustrated), the top piece 2705 and bottom piece 2710 could be configured to form a second spline groove 2740 on the opposite side of the two-piece insert from the illustrated spline groove 2740. The cavities 2745 and/or 2750 could be closed at one or both ends of the drain insert.
Other variations to the drain inserts illustrated in FIGS. 24A&B, 25A&B, 26A&B, and 27A&B are also possible. For instance, the shape of the top spline channels 2415, 2515, 2615, 2715 and the bottom spline channels 2430, 2530, 2630, 2730 could be altered. In addition, the number and shape of ridges and corresponding slots could be varied, according to design choice. Moreover, the position, shape, and proportion of the cavities 2545, 2645, 2650, 2745, and 2750 could be varied.
FIGS. 28A-D each illustrates a side view of a two-piece insert. In each of FIGS. 28A-D, a top piece 2805 is coupled to a bottom piece 2810. Tongues 2840 are consistent with tongues 1335, 1345 described with reference to FIG. 13. FIGS. 28A and 28B illustrate alternative screen-side views showing spline groove 2815. FIGS. 28A and 28C each illustrate gate opening 2825 and pilot holes 2820 that are configured to cooperate with a gate 505 and associated hardware. FIGS. 28B and 28D each illustrate a weeping slot 2830. A given drain insert could include features illustrated, for example, in FIGS. 28A and 28C, FIGS. 28A and 28D, FIGS. 28B and 28C, FIGS. 28B and 28D, FIGS. 28A and 28B (a drain insert with spline grooves 2815 on both sides). Moreover, one or both sides of a two-piece drain insert could include a full-length weeping slot 2310. Other combinations using features disclosed herein are also possible.
FIGS. 29-35 illustrate another variant of the third embodiment of the invention.
FIGS. 29 and 30 are end views. As shown therein, a top piece 2905 is configured to cooperate with a bottom piece 2910. The top piece 2905 includes a tongue 2925, spline channels 2915 and internal lip 2920. The bottom piece 2910 includes spline channels 2930. FIG. 30 shows that the spline channels 2915 and 2930 form spline grooves 2940 in the illustrated two-piece insert when the top piece 2910 is affixed to the bottom piece 2910, for example with adhesive, sonic welding, or other joining process.
FIG. 31 is a sectional view of the drain insert for this variant of the third embodiment, taken at section A-A in FIG. 32. FIG. 31 illustrates a cavity 2945 in the top piece 2905 and a cavity 2950 in the bottom piece 2910. Gate openings 2955, which form a portion of a drainage channel in the drain insert, are also shown. FIG. 31 also makes reference to gate mounting features, namely standoff 2960, split shaft 2965, standoff 2962, and post 2970. The standoff 2960 and split shaft 2695 are configured to cooperate with a pivoting end of a gate 505; the standoff 2962 and post 2970 are configured to cooperate with a slotted end of a gate 505.
FIGS. 32 and 33 provide top views of the drain insert. Pilot holes 3205 facilitate the attachment of the drain insert to portions of a floor member 115, similar to the approach illustrated in FIG. 13. The gates 505, illustrated as part of the drain assembly in FIGS. 33 and 35, include a lip 575 and are generally configured as described with reference to FIGS. 15B and 15D.
SUMMARY In conclusion, embodiments of the invention provide a modified floor member or drain insert configured with openings and/or gates to facilitate drainage from a screened enclosure. The pivoting feature of the gate provides a relatively high-flow option when the gate is pivoted to an open position and a relatively low-flow option when the gate is pivoted to a closed position. The invention can be economically installed with new screened enclosures or retrofitted to existing enclosures. The second and third embodiments may be especially suitable for high-rise balconies or similar installations having no practical access to an outside portion of the screened enclosure. The two-piece insert design, which is applicable to the second or third embodiments, facilitates plastic mold fabrication of drain inserts with one or more spline grooves.
Those skilled in the art can readily recognize that numerous variations and substitutions may be made in the invention, its use and its configuration to achieve substantially the same results as achieved by the embodiments described herein. Accordingly, there is no intention to limit the invention to the disclosed exemplary forms. In addition, although references are made to embodiments and variations of the invention, many of the features disclosed herein can be utilized in combinations not expressly illustrated or described. Nor is there any intent to restrict the materials used to manufacture any of the features described herein. Likewise, milling, extrusion, molding, three-dimensional printing, or other fabrication processes may be used, as applicable to the selected materials.
