Method and Associated Apparatus for Assembling and Testing a Plumbing System

Abstract

A system is provided for enhancing the interconnectability of a bathtub to a plumbing system. More specifically, provided is a flexible conduit and an overflow assembly that allows for a portion of the overflow assembly to be easily located with the wall of a bathtub. The flexible conduit provided allows for adjustability of the conduit to the openings of the bathtub. In addition, provided are methods and apparatus that facilitate testing of a plumbing assembly. Finally, an apparatus and methods are provided that protect portions of the finished bathtub assembly to decrease in the need for replacing said hardware. It is envisioned that aspects and inventions disclosed herein can be used in conjunction to facilitate the interconnection and protection of hardware associated with a bathtub.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-part of U.S. patent application Ser. No. 14/074,442, filed Nov. 7, 2013, which is a Continuation of U.S. patent application Ser. No. 13/691,405, filed Nov. 30, 2012, now U.S. Pat. No. 8,584,272, which is a Continuation of U.S. patent application Ser. No. 13/234,030, filed Sep. 15, 2011, now U.S. Pat. No. 8,321,970, which is a Continuation of U.S. patent application Ser. No. 11/931,681, filed Oct. 31, 2007, now U.S. Pat. No. 8,028,357, which is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/674,862, filed Sep. 30, 2003, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/222,062, filed Aug. 16, 2003, now U.S. Pat. No. 6,637,050, and a Continuation-In-Part of U.S. patent application Ser. No. 10/229,533, filed Aug. 28, 2002, now U.S. Pat. No. 6,675,406, which is a Continuation of abandoned U.S. patent application Ser. No. 09/593,724, filed Jun. 13, 2000.

U.S. patent application Ser. No. 13/691,405 is a Continuation-In-Part of U.S. patent application Ser. No. 10/732,726, filed Dec. 10, 2003, now U.S. Pat. No. 8,302,220, which is a Continuation-In-Part of U.S. patent application Ser. No. 09/954,420, filed Sep. 17, 2001, now U.S. Pat. No. 6,691,411.

U.S. patent application Ser. No. 13/691,405 is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/721,694, filed Nov. 25, 2003, which is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/247,247, filed Sep. 19, 2002.

U.S. patent application Ser. No. 13/691,405 is a Continuation-In-Part of U.S. patent application Ser. No. 12/100,762, filed Apr. 10, 2008, which is a Continuation-In-Part of abandoned U.S. patent application Ser. No. 10/971,895, filed Oct. 22, 2004.

U.S. patent application Ser. No. 13/691,405 is a Continuation-In-Part of U.S. patent application Ser. No. 11/161,933, filed Aug. 23, 2005, now U.S. Pat. No. 7,503,083.

The entire disclosures of the applications and patents listed above are incorporated by reference herein.

This application is also related to U.S. patent application Ser. No. 11/873,200, filed Oct. 16, 2007, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/423,996, filed Jun. 14, 2006, which is a Continuation of U.S. patent application Ser. No. 10/370,545, now U.S. Pat. No. 7,185,529, filed Feb. 20, 2003. The entire disclosures of the applications and patents listed above are incorporated by reference herein.

FIELD OF THE INVENTION

Embodiments of the present invention are generally related to components of a plumbing system associated with a bathtub, shower stall, sink, etc. More specifically, embodiments of the present invention relate to a kit that includes devices that facilitate interconnection of the plumbing system to the bathtub, which allows for testing of the plumbing interconnections, and protects finished hardware associated with the bathtub.

BACKGROUND OF THE INVENTION

During new building construction or renovation of an existing building structure, plumbers often must connect or reconnect bathroom fixtures to the plumbing system. Often plumbers find that interconnecting common bathroom fixtures, such as a bathtub, is difficult and time consuming. “Bathtubs” as referred to herein include a tub with a drain port and an overflow port such that if the drain port is plugged, water will flow into the overflow port and drain through the plumbing system and not out of the tub. Generally, the bathtub is interconnected to the plumbing system by a main drain pipe that is interconnected to the drain port of the bathtub via a horizontal segment, and that is associated with the overflow port of the bathtub via a vertical segment. The two drain segments merge at a tee connector that is also interconnected to the main drain pipe that feeds into a sewer line. During construction, the often heavy bathtub must be aligned properly to interconnect with the drain pipe segment (horizontal) and the overflow pipe segment (vertical) of the drain pipe. Often the drain pipe segments are near a wall, awkwardly oriented, etc. and are, thus, difficult to interconnect to the bathtub.

Once the drain pipe segments are aligned with the bathtub, the drain pipes must usually be blocked for testing. In the past, a plug, bladder, or cap has been employed to facilitate testing. Plugs and/or caps are easily misplaced and are often difficult to install, thereby increasing the time and difficulty of testing the plumbing system.

Another drawback of bathtub assemblies of the prior art is that the finishing hardware commonly associated with a bathtub drain often is damaged during construction. Traditionally, finished hardware made of chrome or brass, for example, is interconnected to the bathtub drain port during construction as a rigid interconnection between the drain pipe and the bathtub is required. Thereafter, workers may damage the often expensive finished hardware by marring, scratching, or even urinating on the same. Thereafter, the plumbing contractor must replace the finished hardware and retest the integrity of the new connection, which adds expense.

Thus it is a long felt need to provide a system that facilitates the interconnection of a bathtub to a plumbing system, enhances the testing of the system, and protects expensive hardware after the assembly is complete.

SUMMARY OF THE INVENTION

Traditionally, an overflow system of a bathtub includes an overflow port that is interconnected to a vertical drain pipe via an elbow.

It is one aspect of the present invention to facilitate this interconnection by providing an elbow with a flange protruding therefrom. More specifically, embodiments of the present invention employ a flange or lip that is spaced from an end of the elbow that will be positioned in the bathtub. The end includes exterior threads that receive a nut, which is designed to detachably receive a cap.

In operation, one end of the elbow is interconnected to the drain pipe and the other end, which is located adjacent to the flange, is placed within the perimeter of an overflow port such that the flange abuts an outer surface of the bathtub, or is spaced therefrom by a compliant washer. The cylindrical fitting is then interconnected to the elbow which locates the other, closed end of the cylindrical fitting within the bathtub. The nut is used to sandwich the bathtub between the nut and the flange which provides a generally rigid connection. Some embodiments of the present invention also employ a washer between the tub and the nut.

It is a related aspect of the present invention to selectively block fluid flow through the overflow assembly. More specifically, the closed portion of the cylindrical fitting acts as a plug for testing of the plumbing system. After testing is complete the closed portion may be cut, or otherwise removed, to allow fluid flow through the overflow assembly. If additional testing is required, traditional methods of plugging the overflow assembly may be employed.

It is another aspect of the invention to provide a method of installing a drain assembly that can be accomplished by one individual. A related aspect of embodiments of the invention is to provide a method of installing a bathtub drain assembly that allows for ease in leak testing. Yet another aspect of embodiments of the present invention is to provide a method of installing the drain assembly that eliminates the need for the removal of a strainer body often associated with drain assemblies. In accordance with these and other aspects, one method includes inserting an L-shaped drain pipe having a threaded upper end and an annular flange covered by a membrane, through a drain port of the bathtub, such that the annular flange rests on a bottom surface of the bathtub. Next, a lock washer is threadingly engaged to the threaded portion. The other end of the L-shaped drain pipe is then connected to the drain system of the building. The assembly can then be tested for leaks. Once it is determined that no leaks are present, the membrane is removed from the flange on the upper end of the drain pipe. Finally, a finished cover is installed on the annular flange.

It is yet another aspect of the present invention to provide a bathtub drain pipe assembly that facilitates integration of the various drain pipes mentioned thus far to the bathtub. Embodiments of the present invention thus include a flexible hollow tube instead of rigid drain pipes that simplifies the installation of the bathtub to the plumbing system. The flexible tube of embodiments of the present invention has the added benefit of being easily modifiable and possesses a smooth inner surface to prevent the often unsanitary trapping of fluid or debris within the flexible hollow tube.

That is, it is one aspect of embodiments of the present invention to provide a system that facilitates the installation of a bathtub to a plumbing system. More specifically, instead of utilizing rigid pipes to direct fluid from an overflow assembly or the drain assembly of the bathtub, embodiments of the present invention employ flexible pipes. One embodiment of the present invention, preferably employs a flexible pipe that connects the overflow assembly of a bathtub to a tee connector. Yet another flexible pipe is employed between the drain and the tee connector. The tee connector is also interconnected to a rigid main waste pipe of the plumbing system. Another embodiment of the present invention provides a single flexible hose wherein the tee connector is directly interconnected to the drain assembly of a bathtub, for example. In such embodiment, the tee connector is also interconnected to the main drain pipe of the plumbing assembly.

It is contemplated that the flexible portions of the pipes described herein may be cut to length as needed. Often, as one skilled in the art will appreciate, plumbing systems are not perfectly aligned with the overflow or drain ports of a bathtub. In the past, a plumbing contractor would be required to alter the plumbing system to account for the misalignment, an expensive and time consuming undertaking. Alternatively, expensive modifications related to the installation of the bathtub, sink, etc. would have to be performed. Some plumbing contractors exert undesired force to move parts into alignment, which stresses the rigid pipes and makes them susceptible to leaking, breakage, etc. Thus, embodiments of the present invention provide a system wherein flexible pipes are provided that may be adjusted to a preferred size (e.g. by cutting) and selectively bent to accommodate misalignments. This aspect of the present invention is desirable because the addition of multiple elbows, for example, is not required. The addition of multiple elbows not only increases the chances for leaks, but also creates a complicated flow path for drainage water that can add to the instances of clogging. As will be apparent to one skilled in the art, the robustness offered by embodiments of the present invention enables vertical or horizontal adjustments that are superior to the prior art methods.

Yet another aspect of embodiments of the present invention is to provide a system and method that can be installed on virtually any type of bathtub. More specifically, the horizontal or vertical distances between the drain port and the overflow port can vary from bathtub to bathtub. The robustness provided by the flexible overflow or drain pipes of the present invention, and the ability to customize the same, allows for desired accommodation for bathtubs of various type/design. Thus, contractors no longer need to customize a plurality of rigid tubes as embodiments of the present invention allow for easy cutting and modifying of flexible tubes to meet their requirements.

It is another aspect of embodiments of the present invention to provide a system and method that can be used with common overflow and drain assemblies. More specifically, one embodiment of the present invention is used in conjunction with the overflow assembly described in the U.S. patents and patent applications listed herein and those described in U.S. Pat. Nos. 6,618,875, 6,622,317, and 7,017,199. The flexible pipes described herein are also adapted to be used with drain assemblies provided in U.S. Patent Application Publication Nos. 20070044230, 2006009019, and 20060096018 and U.S. Pat. Nos. 6,317,906, 6,173,459, 6,640,358, 6,418,570, 6,691,411 and 6,546,573, the entire disclosures of which are incorporated by reference herein. Embodiments of the present invention have the ability to be bonded or otherwise interconnected easily to overflow assemblies and drain assemblies shown and referred to herein, or to other commonly used overflow and/or drain assemblies.

Thus, it is a related aspect of the present invention to provide a kit to be used by plumbing contractors. More specifically, it is contemplated that a kit containing overflow assemblies, drain assemblies, finishing hardware, etc. may be supplied in a single package that includes flexible pipes. Further, it is contemplated that such flexible pipes may be provided in lengths that are purposely longer than required to enable a contractor the ability to trim the flexible pipes as needed or desired.

It is yet another aspect of embodiments of the present invention to provide flexible pipe sections that employ a generally smooth inner surface. More specifically, although certain types of flexible pipes are generally well known, flexible pipes of the prior art often employ bellows that have internally and externally disposed corrugations. Although such a configuration is acceptable in some arenas, in the plumbing art it often is not. More specifically, internally disposed corrugations are apt to retain fluids and/or debris from the bathtub, such as hair, dirt, skin etc. This debris and related fluid is a breeding ground for germs, bacteria, and mold. Thus building codes often require that drain pipes must be generally smooth to provide laminar flow that facilitates the drainage of all fluid from the bathtub and associated pipes.

It is still yet another aspect of the present invention to provide a protective cover that interconnects to the installed drain assembly. More specifically, a flange of the protective drain cover is superimposed over the flange of a waste water strainer located in a bathtub, sink or the like. A lip located about the outer perimeter of the flange of the cover fits over the outer periphery of the flange of the waste water strainer and centers the cover on the strainer. A cylindrical wall, which extends from the flange of the cover, is positioned downwardly through a cylindrical wall of the waste water strainer. The two cylindrical walls are spaced from each other by one or more seals that are positioned in grooves.

It is an aspect of the embodiment of the present invention to combine some or all of the above-described aspects to provide a system that facilitates interconnection of the bathtub to the plumbing system of a structure. More specifically, it is contemplated to use aspects described above, provided below, or apparent to one skilled in the art in conjunction to alleviate all of the difficulties noted above that are associated with interconnecting a bathtub to a plumbing system of a structure. For example, one skilled in the art will appreciate the overflow assembly can be easily integrated with the flexible pipes described above to expand the interconnection options available to a plumber. In addition, the protective drain cover may also be used. It is contemplated that the above described aspects of the present invention will provide a complete kit wherein all of the necessary components will be included to aid the plumber in interconnecting a bathtub to the plumbing of a structure, facilitate testing of the same and protecting fragile and expensive components thereof, which will increase efficiency and decreasing costs of the operation.

The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.

FIG. 1 is a partial perspective view of a bathtub;

FIG. 2 is a cross-sectional view of FIG. 1;

FIG. 3 is an exploded perspective view of an overflow assembly of one embodiment of the present invention;

FIG. 4 is a cross-sectional assembled view of the overflow assembly shown in FIG. 3;

FIG. 5 is an exploded perspective view of an alternate embodiment of an overflow assembly;

FIG. 6 is a cross-sectional, assembled view of the overflow assembly shown in FIG. 5;

FIG. 7 is a perspective view of a cylindrical fitting employed in overflow assemblies of some embodiments of the present invention;

FIG. 8 is an exploded view of an alternate embodiment of an overflow assembly that employs a one-piece overflow pipe and cylindrical fitting;

FIG. 9 is a perspective view of the one-piece overflow pipe and cylindrical fitting shown in FIG. 8;

FIG. 10 is an exploded perspective view of a drain assembly of one embodiment of the present invention;

FIG. 11 is a side elevation view of the drain assembly shown in FIG. 10 interconnected to the bathtub;

FIG. 12 is a side elevation view of a prior art interconnection horizontal and vertical drain pipes;

FIG. 13 is a perspective view of a flexible overflow pipe;

FIG. 14 is a side elevation view of the flexible conduit of FIG. 13 interconnected to the bathtub;

FIG. 15 is a side elevation of horizontal and vertical flexible conduits interconnected to the bathtub;

FIG. 16 is a partial cross-section of a flexible pipe of one embodiment of the present invention;

FIG. 17 is a partial perspective view of a bathtub showing a test cap interconnected to the overflow port;

FIG. 18 is a perspective view of a test cap of one embodiment of the present invention;

FIG. 19 is a cross-sectional view of the test cap of FIG. 18 interconnected to an overflow pipe;

FIG. 20 is a perspective view of an alternative embodiment of a test cap;

FIG. 21 is a cross-sectional view of the test cap of FIG. 20 shown interconnected to an overflow pipe;

FIG. 22 is a side elevation view of an alternative embodiment of the test cap interconnected to an overflow pipe;

FIG. 23 is a front elevation view of another embodiment of the test cap having a removable diaphragm;

FIG. 24 is a rear perspective view of the test cap shown in FIG. 23;

FIG. 25 is a perspective view of a protective cover and drain;

FIG. 26 is a cross-sectional view of the protective cover shown in FIG. 24; and

FIG. 27 is a cross-sectional view of an alternate embodiment of the protective cover.

To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:

#   Component
2   Overflow assembly
6   Bathtub
10  Drain port
14  Overflow port
18  Elbow
22  Overflow pipe
26  Tee connector
30  First end
34  Second end
38  Flange
42  Shoulder
46  Cylindrical fitting
50  Threads
54  Diaphragm
58  Outer surface
62  Wall
66  Inner surface
70  Washer
74  Nut
78  Lug
82  Threads
86  Cap
90  Notch
94  Protrusions
98  Ring
102 Cutting tool
106 Opening
110 Drain assembly
112 Edge
114 Tub floor
118 Drain pipe flange
122 Nut
126 Cylindrical portion
130 Threads
134 Drain pipe
138 Membrane
140 Cover
144 Drain closure
148 Flexible conduit
152 Coil
156 Flexible material
160 Web
164 Axis
176 Test cap
180 Cylindrical body
184 Flange
188 Face
192 Interior threads
196 Inner surface
200 Protective cover
204 Opening
208 Flange
212 Tubular wall
216 Groove
220 Seal
224 Strainer
228 First portion
232 Second portion
236 Conical portion

It should be understood that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

Referring now to FIGS. 1-9 an overflow assembly 2 adapted for interconnection to a bathtub 6 is provided. The overflow assembly 2 is adapted to be used in conjunction with a bathtub 6 having a drain port 10 and an overflow port 14. The overflow port 14 receives an L shaped elbow 18 that leads into an overflow pipe 22 that eventually feeds into a tee-connector 26. The tee-connector 26 also receives fluid from the drain port 10 of the bathtub 6 and has an opening that connects to the sewer system of the structure.

Turning now specifically to FIGS. 2-4, an overflow assembly of one embodiment of the present invention is provided. Here, the elbow 18 includes a first end 30 and a second end 34 wherein a flange 38 is spaced from the first end 30. Thus, the first end 30 comprises a lip that protrudes from the flange 38. The first end 30 is adapted to receive a shoulder 42 of a cylindrical fitting 46 that also includes an outer surface with a plurality of threads 50 and may have a diaphragm 54 situated on one end thereof.

In operation, the flange 38 is adapted to abut an outer surface 58 of the bathtub 6, thereby placing the first end 30 at least partially within the thickness of the bathtub wall 62 or away from an inner surface 66 of the bathtub 6 which facilitates alignment of the overflow port and the overflow assembly 2. After the elbow 18 is properly aligned and engaged within the overflow port 14 of the bathtub 6, the cylindrical fitting 46 is interconnected thereto wherein the shoulder 42 is placed in contact with the first end 30 of the elbow 18. A washer 70 is then placed around the cylindrical fitting 46 and in abutting relationship with the inner surface 66 of the bathtub 6. A nut 74 having a plurality of externally protruding lugs 78 and internal threads 82 is then screwed on to the threads 50 of the cylindrical fitting 46, thereby sandwiching the wall 62 of the bathtub 6 between the flange 38 and the washer 70. The lugs 78 of the nut 74 are adapted to receive an inner surface of a cap 86. The cap 86 also employs at least one notch 90 that allows for water to flow from the cap 86 through the elbow 18 and into the overflow pipe 22 of the plumbing system.

After the overflow system is interconnected to the bathtub, testing it is often required. Often such testing of the overflow assembly 2 must be blocked. Thus, as briefly described above, the cylindrical fitting 46 may include a diaphragm 54 that prevents flow of liquid therethrough. After testing is complete the diaphragm 54 may be cut away to provide a flow path from the notch 90 of the cap 86 into the elbow 18. No additional hardware, such as a test cap, is needed to perform testing.

Referring now to FIGS. 5 and 6, an alternate embodiment of an overflow assembly 2 is provided. More specifically, the nut 74 described above includes a plurality of protrusions 94 aligned on a ring 98 that is positioned adjacent to the plurality of the lugs 78. The protrusions 94 allow for enhanced interconnectability between the nut 74 and the cylindrical fitting 46 by providing a plurality of finger holds.

Referring now to FIG. 7, the cylindrical fitting 46 of the overflow assembly 2 of one embodiment of the present invention is provided. As mentioned above, it is often desirous to maintain the integrity of the overflow assembly 2 such that fluids or air are maintained within the plumbing assembly, i.e. plugged. After any required testing is complete, a cutting tool 102 is employed to remove the diaphragm 54 of the cylindrical fitting 46, thereby providing an opening 106 for fluids.

Referring now to FIGS. 8 and 9, yet another variation of the above-identified overflow assembly is provided. Here, a one-piece unit is provided wherein the cylindrical fitting 46 and the elbow 18 are rigidly interconnected. In addition, one skilled in the art will appreciate that at least a portion of the overflow pipe 22 may also be rigidly interconnected to the elbow 18. This configuration omits at least two joints in the system, which reduces the likelihood of leaks between components. One skilled in the art will also appreciate that a diaphragm may also be included in this embodiment of the present invention that is cut away to provide an opening 106 after testing is performed.

Referring now to FIGS. 10 and 11, the drain assembly 110 for interconnecting the bathtub to the plumbing system of one embodiment of the present invention is shown. Here, similar to the overflow assembly, the drain assembly must be rigidly interconnected to the bathtub 6. Thus embodiments of the present invention employ a drain assembly 110 wherein the tub floor 114 is sandwiched between a drain pipe flange 118 and a nut 122. In operation, the drain pipe flange 118 includes a cylindrical portion 126 extending therefrom that includes a plurality of threads 130. The drain pipe flange 118 is mated with a drain pipe 134 wherein the nut 122 is threaded on the drain pipe 134 prior to the marriage of the cylindrical portion 126 and the drain pipe 134. The nut 122 is brought up to the threads 130 and tightened such that the tub floor is sandwiched between the drain pipe flange 118 and the nut 122 to secure the drain assembly to the drain port 10 of the bathtub 6. To test the system a membrane 138 may be employed to block flow to the drain pipe 134. After testing is completed, a cover 140 and drain closure 144, which are common in the art, may be incorporated.

Referring now to FIGS. 12-15, a method of facilitating interconnection of the overflow pipe 22 and the drain pipe 134 is provided. FIG. 12 shows the prior art method of interconnecting drain pipes and flow pipes to a bathtub 6 wherein the rigid overflow pipe 22 is interconnected to the elbow 18 of the overflow assembly 2 and a rigid drain pipe 134 is horizontally interconnected from a connector associated with the drain port 10. These two rigid pipes merge at a tee-connector 26 and into the main drain pipe of the plumbing system. As one skilled in the art will appreciate, interconnection of these rigid pipes is often difficult, especially when they are misaligned due to engineering errors or errors in interconnecting of the individual pipes to the tee-connectors 26, for example. Often, the interconnection of the bathtub to the overflow pipe 22 and drain pipe 134 will cause frustration, delays and increased costs.

Referring now to FIGS. 13 and 14, this problem has been addressed by an embodiment of the present invention that provides a flexible conduit 148 that leads from the elbow 18 of the overflow assembly 2 to the tee-connector 26. It is envisioned that the flexible conduit 148 of this embodiment of the present invention be corrugated, however, be not susceptible to the drawbacks of using a corrugated tube. More specifically, as one skilled in the art will appreciate, the use of corrugated tubing, to allow for selective adjustments of tube bends is common. However, the use of a corrugated surface is not desirable and is often counter building codes as waste and fluid can gather in the corrugations provided in the inner diameter of the conduit, thereby providing a breeding ground for a mold and germs. Thus the flexible conduit 148 of embodiments of the present invention employ a coating that maintains flexibility but yet eliminates at least the corrugations in the inner surface of the flexible conduit 148.

Referring now specifically to FIG. 15, the flexible conduit 148 as described above may be employed in another way. That is, FIG. 14 shows the flexible conduit 148 extending from the overflow assembly 2 into the tee-connector 26 that is associated directly with the drain port 10. More often, it is desirable to provide a vertical overflow pipe 22 and a horizontal drain pipe 134. These pipes may be made of the flexible conduit as described above and interconnected as traditionally done to the tee-connector 26 that is associated with the main drain pipe of the plumbing system. Because the flexible conduit 148 as provided is pliable, it is easily cut. Thus plumbers may use the flexible conduit 148 as they would use rigid conduit and selectively cut them to lengths to interconnect to traditionally located tee-connectors 26.

Referring now to FIG. 16, the flexible conduit 148 of one embodiment of the present invention is shown. Embodiments of the present invention employ a ribbed, bellowed, or coiled 152 (e.g., a helical coil) structure of rigid material that is apt to bend due to its coiled arrangement. In one embodiment the ribbed or coiled material is sufficiently rigid to retain a substantially circular cross section, thus providing a substantially uniform flow path for liquid transportation through the interior of such ribbed, bellowed, or coiled structure. In certain embodiments the ribbed/bellowed/coiled material employed is different that the material comprising the remainder of the conduit/pipe formed. For example, a more pliable material may be to coat the ribbed/bellowed/coiled material.

To provide a flow path for fluid, the rigid material is coated with a flexible material 156 that is, preferably, substantially kink resistant. Thus between portions of the coil a web 160 will exist. In one embodiment such web material, when combined with the coiled substructure is not completely smooth. That is, in one embodiment, the flexible pipe comprises a coil 152 coated on an inside surface and an outside surface with a flexible material 156, wherein a web 160 is formed between portions of the coated coil 152. Further, in this embodiment the coated coil and the web 152 are aligned along a common axis 164 that bisects their respective thicknesses. In other embodiments, this web/coil combination provides a substantially smooth flowpath that is not apt to trap debris or water. In addition, the coil/flexible material combination is tightly bonded yet easy to cut, thereby facilitating customization of embodiments of the present invention. Those skilled in the art will appreciate that instead of a coil 152, a plurality of spaced rings may be employed that are also coated with a flexible material 156. Other methods for making the structure as disclosed will be obvious to one skilled in the art. Certain embodiments of the present invention employ plastic (such as PVC) as the flexible material 156 and plastic (such as PVC) as the material for the coil 152. However, those skilled in the art will appreciate that other flexible materials such as rubber, acrylonitrile butadiene styrene (ABS), polycarbonate, polypropylene, and nylons, to name a few, may be employed without departing from the scope of the invention. The coil system may be made of a metallic material, PVC, carbon fiber, reinforced nylons, hard durometer rubbers, to name a few, without departing from the scope of the invention.

Referring now to FIGS. 17-24, a test cap 176 of one embodiment of the present invention is provided. As mentioned above, it is often desirous to plug the overflow port 14 and/or drain port 10 of the bathtub to facilitate testing. As also described above, this is most preferably done with a diaphragm that omits the need for a test cap 176. However, if testing needs to be performed subsequent to removal of a diaphragm, a test cap 176 can be used.

Referring now to FIGS. 18 and 19, a test cap 176 of one embodiment of the present invention is provided with a cylindrical body 180 having a flange 184 positioned thereon. The flange 184 has a face 188 that receives a diaphragm 54 and includes internally located threads 192 that receive the threads of the cylindrical fitting 42 of the overflow assembly 2, similar to that described above. The test cap 176 of this nature can be used on overflow assemblies as described above that include a diaphragm 54 if further testing is required. After testing is completed, the diaphragm 54 of the test cap 176 of this embodiment of the present invention may be cut away to provide an opening 106 as described above.

Referring now to FIGS. 20 and 21 a test cap 176 of one embodiment of the present invention is shown. Here, a traditional plug having threads is used. However, this embodiment of the present invention also includes a diaphragm 54 positioned on one end that may be cut-away after testing is complete.

Referring now to FIGS. 22-24, yet another version of the test cap 176 is provided with an inner surface 196 of malleable material that helps seal the interconnection of the test cap 176 and the overflow elbow 18. That is, by interconnecting the test cap 176 onto the external threads of the overflow elbow 18, the end of the overflow assembly 2 will deform the inner surface of the test cap 176 somewhat to create a seal. It is also envisioned that a test cap 176 of this embodiment of the present invention employs a diaphragm 54 that can be cut away if needed.

Referring now to FIGS. 25-27, a protective drain cover 200 is provided. Here, the protective cover 200 having an opening 204 therethrough and a flange 208 is shown.

Emanating from the flange 208 is the tubular wall 212 having a groove 216 positioned therearound. The groove 216 is adapted to receive at least one seal 220. The protective cover 200 is adapted to be associated with a strainer 224 of the drain assembly, thereby positioning the flange 208 of the protective cover 200 over the flange 118 of the strainer 224. In addition, the protective cover 200 includes an edge 112 that slightly curves downwardly to protect an edge of the strainer 224. As described above, the strainers 224 are often made of a brass or chrome which is easily damaged. Thus in operation, the tubular wall 212 of the drain cover 200 feeds into an opening of the strainer 224. The seals 220 are then disposed between the outer surface of the tubular wall 212 and the inner surface of the strainer 224. Thus the drain assembly 110 is protected during construction. After construction is completed, the protective cover 200 is removed and the drain assembly 110 remains within the bathtub 6.

As disclosed in U.S. Pat. No. 7,503,083, numeral 200 may also be viewed as a waste water insert. Insert 200 has a flange 208 with the periphery thereof terminating in a downwardly extending lip 112. As shown in FIGS. 26 and 27, the lip 112 extends downwardly and over the outer perimeter of the strainer flange 118. The lip 112 engages the tub floor 114 (see FIG. 11) when installed.

Insert 200 has a downwardly extending wall 212 which surrounds a center opening 204. The diameter of wall 212 is less than the diameter of the cylindrical wall of strainer 224 so that a space exists between the two walls. The lip 112 on the outer perimeter of the flange 208 of insert 200 centers the cylindrical wall 212 within the cylindrical wall of strainer. In one embodiment, the waste water insert 200 includes a wall 212 with a cylindrical first portion 228 and a cylindrical second portion 232 with a conical portion 236 therebetween. The diameter of the cylindrical first portion 228 is greater than the diameter of the cylindrical second portion 232 such that the space between the insert and the strainer is reduced adjacent to the cylindrical first portion 228.

The wall 212 extends downwardly and has a first groove 216 in the lower end. The groove 216 receives a resilient ring member 220 that engages the cylindrical wall 212 of the strainer 224 to hold the insert 200 in place. In one embodiment, the resilient ring member 220 is an O-ring. Alternatively, the waste water insert 200, as shown in FIG. 26, has a second groove in spaced relation to the first groove 216 with a raised surface therebetween. The second groove receives a second resilient ring member 220 that also engages the cylindrical wall 212 of strainer 200. Additional grooves and rings may be added as desired.

The insert is installed by inserting the cylindrical wall 212 of the insert 200 into the opening 10 of the strainer 224 until the insert is in place. At this point the resilient ring or rings of the insert will engage the cylindrical wall of the strainer 224 to hold the insert 200 in place. No tools are required and the inserts are quickly, easily, and securely installed to achieve their required purpose.

While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims.

Claims

1. A plumbing system for interconnection with a bathtub that has an overflow port and a drain port, comprising:

an overflow assembly adapted to be associated with the bathtub, comprising: an overflow pipe including an upper end and a lower end; an elbow between said upper end and said lower end, said upper end having threads and being adapted to fit completely through the overflow port of the bathtub; a lip extending radially outwardly from an outer surface of the overflow pipe between said elbow and said upper end, the lip adapted to engage an outer surface of the bathtub adjacent to the overflow port; a nut element associated with said overflow pipe adapted to secure said overflow pipe to an end of the bathtub wherein a wall of the bathtub is positioned between said lip and said nut element, said nut element comprising threads compatible with said threads of said upper end and said nut element having a plurality of cap retention elements extending radially from said nut element; and a cap selectively interconnected to said nut element; and

a flexible conduit interconnected to said lower end of said overflow pipe.

2. The assembly of claim 1, wherein said cap defines a fluid passing passage.

3. The assembly of claim 1, wherein said cap covers substantially all of said nut element.

4. The assembly of claim 3, wherein said cap is adjustably retained to said nut element by the cap retention elements, which are circularly spaced and comprise small lips.

5. A plumbing system for interconnection with a bathtub that has a bottom, sidewalls, end walls, an overflow port, and a drain port, comprising:

an overflow assembly adapted for interconnection to the bathtub, comprising: an overflow pipe having an elbow portion defining an upper end portion and a lower end portion, said upper end portion having an outer end defining an inlet and threads on an outer surface thereof; a lip extending radially outwardly from said outer surface of said overflow pipe between said elbow portion and said upper end portion and being spaced from said inlet; a nut element with a threaded portion that is compatible with said threads of said overflow pipe for mounting said nut element to said upper end portion, said nut element having a series of radially extending cap retention elements that are spaced about a longitudinal axis defined by said nut element, there being gaps between each of said radially extending cap retention elements; and a cap retained in a position of attachment to said radially extending cap retention elements, said radially extending cap retention elements being received within said cap; and a flexible conduit interconnected to said lower end portion of said overflow pipe.

6. A plumbing system for interconnection with a bathtub that has an overflow port and a drain port, comprising:

an overflow assembly adapted for interconnection to the bathtub, which has a bottom, side walls, end walls, and an overflow port in one end wall, comprising: an overflow pipe with an elbow portion defining an upper end portion and a lower end portion, said upper end portion having an outer end defining an inlet, said upper end having threads on an outer surface thereof; a lip extending radially outwardly from said outer surface of the overflow pipe between said elbow portion and said upper end portion and being spaced from said inlet; a nut element with a threaded portion that is compatible with said threads of said overflow pipe, said nut element having an outer periphery with a series of radially extending lugs that detachably engage an inner surface of a cap that fits over said nut; and a flexible conduit interconnected to said lower end portion of said overflow pipe.

7. The assembly of claim 6, wherein said nut element and said radially extending lugs constitute a single-piece unit.

8. The overflow assembly of claim 6, further comprising a sealing element associated with said outer end that closes the inlet to fluid flow.

9. A plumbing system for interconnection with a bathtub that has an overflow port and a drain port, comprising:

an overflow assembly that includes: an overflow pipe with an elbow portion defining an upper end portion, which is adapted for interconnection with the overflow port, and a lower end portion, which is adapted for interconnection with a wastewater drain assembly, said upper end portion having an outer end defining an inlet, said upper end having threads on an outer surface thereof; a lip extending radially outwardly from said outer surface of said overflow pipe between said elbow portion and said upper end portion and being spaced from said inlet; a nut element with a threaded portion that is compatible with said threads of said overflow pipe, said nut element having an outer periphery with a series of radially extending lugs that detachably engage an inner surface of a cap that fits over said nut; and wherein said lower end portion is adapted for interconnection with a waste water drain assembly by way of a flexible conduit.