PRE-FORM FOR DRAIN INSTALLATION

Abstract

A pre-form for drain installation is provided. The pre-form comprises a cap portion, a bottom portion, and an outer portion. The cap portion defines an interior for receiving a top end of an upwardly extending drain pipe and is configured to cover an opening of the drain pipe. The bottom portion is detachedly coupled to the cap portion and comprises an aperture through which the drain pipe may pass so as to enable the bottom portion to slide along the length of the drain pipe. The outer portion is coupled to and extends upwardly from the bottom portion so as to define a perimeter for displacing concrete proximate to the drain pipe when inserted into a wet concrete flooring surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a utility application of, and claims priority to, U.S. Design Patent Application No. 29/594,612, filed on Feb. 21, 2017, which claims priority to Mexican Design Patent Application No. MX/f/2016/003927, filed on Dec. 6, 2016, the entirety of both hereby incorporated by reference.

BACKGROUND

Most homes use basic systems for plumbing and drain systems. A main water line usually comes into a home through its foundation. From this location, the water line may run to a water heater, which generates hot water.

A plumbing drain trap is a shaped pipe located below or within a plumbing fixture such as a toilet, a sink, or a shower drain. A trap can be a U-, S-, or J-shaped trap, although U- and J-shaped traps are the most common traps used today. The various shapes are each named for the bends in the traps, which are used to prevent sewer gases from entering buildings through drain pipes. The bends in the traps are shaped to retain a small amount of water after use of the fixture. The water in the trap creates a seal that prevents sewer gases from passing from the drain pipe back into the building.

However, known plumbing traps have certain disadvantages. Many installations require shallow traps in order to fit against a concrete floor, whether that concrete floor is on a first floor or a basement floor, or for a second story installation. In the United States, basement floors are typically concrete floors so a shallow trap must be used for basement drain fixtures. The height of a trap seal is measured from the bottom of a trap arm at an outlet to the top of the trap dip, also know as the crown weir. A standard trap height may be 50 mm, for example, but a shallow trap may only have a trap height of 15 mm, for example. When a shallow trap is used, however, the amount of water in the trap is decreased compared to the amount in a regular trap, and regular evaporation of water in the trap may cause the water seal to be broken more quickly, thereby allowing sewer odors and gases to enter into the building.

In addition, in some other regions, such as Latin America, floor drains are typically placed next to a toilet in addition to in a shower. While traps connected to a shower drain or a toilet are easy to refill on a regular basis by running the shower or flushing the toilet, in order to maintain a proper seal for a floor drain pipe with a known plumbing trap, water must be poured into the drain on a regular basis. Otherwise, the water within the trap may evaporate and the water seal may be broken if air can pass through the bend in the trap, thereby allowing sewer odors and gasses to enter into the building.

Further, installing floor drains can be difficult because more than one professional is typically involved in the installation process. In a standard installation, a plumber will install the sub-floor plumbing components and then leave a drain pipe extending above an estimated floor height that will extend to a desired fixture. Then, a flooring specialist will finish the flooring above the sub-floor plumbing. Concrete is often poured around the drain pipe and then a finish flooring surface is installed above the concrete. Once the concrete is poured, however, it is difficult, if not impossible, to remove the drain pipe to cut it to the proper height. In order to cut the drain pipe below the flooring surface after the concrete is poured, the flooring specialist must chisel the cement around the drain pipe so that there is sufficient clearance for tools to cut the drain pipe below the flooring surface. Understandably, manually chiseling cement surrounding the drain pipe is often an approximated process and can result in cracking of the drain pipe. As such, an installed floor drain may not seal completely with the drain pipe or surrounding concrete, thereby resulting in unwanted leaks. Additionally, if the drain pipe is cut before the concrete is poured, it is difficult to determine the desired length of the drain pipe necessary to make the floor drain sit flush on the finished flooring surface.

Thus, an improved method for determining the height of the drain pipe and installing a floor drain flush with the flooring slab is desired.

BRIEF SUMMARY

In an exemplary embodiment, an improved method of installing a drain fixture is provided. First, a sub-floor plumbing system comprising an upwardly extending drain pipe is installed. Next, a pre-form is positioned on a top end of the drain pipe. The pre-form comprises a cap portion that substantially covers an opening of the drain pipe as well as a bottom portion that is detachedly coupled to the cap portion and an outer portion. Next, a concrete flooring surface is built proximate to the drain pipe. While the concrete is still wet, a downward force is applied to the bottom portion of the pre-form so as to cause the cap portion to detach from the bottom portion. The bottom portion of the pre-form is slid down the length of the drain pipe until the bottom portion is at least partially inserted into the concrete flooring surface proximate to the drain pipe. The cap portion remains positioned on the top end of the drain pipe. After the concrete sets, the cap portion and the bottom portion of the pre-form are removed. The drain pipe is cut to a desired length, thereby resulting in a shortened drain pipe. Lastly, a drain may be installed on a top end of the shortened drain pipe.

In an exemplary embodiment, a pre-form for drain installation is provided. The pre-form comprises a cap portion, a bottom portion, and an outer portion. The cap portion defines an interior for receiving a top end of an upwardly extending drain pipe and is configured to cover an opening of the drain pipe. The bottom portion is detachedly coupled to the cap portion and comprises an aperture through which the drain pipe may pass so as to enable the bottom portion to slide along the length of the drain pipe. The outer portion is coupled to and extends upwardly from the bottom portion so as to define a perimeter for displacing concrete proximate to the drain pipe when inserted into a wet concrete flooring surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the following descriptions taken in conjunction with the accompanying drawings.

FIG. 1 depicts an elevational view of a first prior art floor drain installation;

FIG. 2 depicts an elevational view of a second prior art floor drain installation;

FIG. 3 depicts an perspective view of an improved drain installation, in accordance with one embodiment of the present disclosure;

FIG. 4 depicts a cutaway view of the improved drain installation of FIG. 3, in accordance with one embodiment of the present disclosure;

FIG. 5 depicts a depicts a magnified cutaway view of the improved drain installation of FIG. 4, in accordance with one embodiment of the present disclosure;

FIG. 6 depicts a cutaway view of an improved drain installation, in accordance with one embodiment of the present disclosure;

FIG. 7 depicts a cutaway view of the improved drain installation of FIG. 3, in accordance with one embodiment of the present disclosure;

FIG. 8A depicts a perspective view of a first pre-form of the improved drain installation of FIG. 3, in accordance with one embodiment of the present disclosure;

FIG. 8B depicts a perspective view of a second pre-form of the improved drain installation of FIG. 3, in accordance with one embodiment of the present disclosure; and

FIG. 9 depicts an perspective view of an improved drain installation, in accordance with one embodiment of the present disclosure.

FIG. 10 depicts a perspective view of a pre-form for drain installation, in accordance with one embodiment of the present disclosure.

FIG. 11 depicts a top view of the pre-form for drain installation of FIG. 10, in accordance with one embodiment of the present disclosure.

FIG. 12 depicts a bottom view of the pre-form for drain installation of FIG. 10, in accordance with one embodiment of the present disclosure.

FIG. 13 depicts a side view of the pre-form for drain installation of FIG. 10, in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

Various aspects of a drainage fitting and related methods for installing a drainage fitting according to the present disclosure are described. It is to be understood, however, that the following explanation is merely exemplary in describing the devices and methods of the present disclosure. Accordingly, any number of reasonable and foreseeable modifications, changes and substitutions are contemplated without departing from the spirit and scope of the present disclosure.

FIG. 1 depicts an elevational view of a first prior art floor drain installation 100. The first prior art drain installation 100 may comprise a drain pipe 102 extending upwardly from a plumbing trap 104 to a fixture, such as a floor drain 108. The installation 100 may further comprises a drain outlet 106 connected to the main sewer line (not shown). Before the installation 100 is completed, the drain pipe 102 extends above a flooring slab and must be cut to the appropriate length to allow the floor drain to sit flush with a finished flooring surface 112.

FIG. 2 depicts an elevational view of a second prior art floor drain installation 200. The second prior art drain installation 200 may comprise a first drain pipe 202 extending upwardly from a connection 206 and a plumbing trap 204 to a fixture, such as a floor drain 208. The connection 206 may also connect to a second drain pipe 210, which may be connected to a second fixture, such as a sink 218. A connection 212 may be connected to the plumbing trap 204 at a second end. A third drain pipe 214 may extend from the connection 212, which may be connected to an elbow 218 and a third fixture, such as a toilet 216. A drain outlet (not shown) may also extend from the second connection 212 and may be connected to the main sewer line. In an embodiment, the first and second connections 206, 218 may be T- or Y-shaped connections. Before the installation 200 is completed, the drain pipes 202 and 214 extend above a flooring slab and must be cut to appropriate lengths to allow the fixtures to sit flush with or on a finished flooring surface.

As depicted in FIGS. 1 and 2, after installation, the fixtures 108, 208, and 216 preferably sit flush with or on a finished flooring surface 112 installed above a concrete slab 110. In order to make such a prior art installation 100, 200, however, a plumber will install the sub-floor plumbing components and then leave the drain pipes 102, 202 extending above an estimated floor height that will extend to a desired fixture. Then, a flooring specialist will finish the flooring above the sub-floor plumbing. Concrete 110 is often poured around the drain pipe and then the finished flooring surface 112 is installed above the concrete 110. Once the concrete 110 is poured, however, it is difficult, if not impossible, to remove the drain pipes 102, 202 in order to cut them to the proper height. In order to cut the drain pipes 102, 202 below the flooring surface after the concrete 110 is poured, the flooring specialist must chisel the concrete 110 around the drain pipes 102, 202 so that there is sufficient clearance for tools to cut the drain pipes 102, 202 below the finished flooring surface 112, which can be a difficult process. But if the drain pipes 102, 202 are cut before the concrete 110 is poured, it is difficult to determine the desired length of the drain pipes 102, 202.

FIG. 3 depicts a perspective view of an improved drain installation 300, in accordance with one embodiment of the present disclosure. FIG. 4 depicts a cutaway view of the improved drain installation 300 of FIG. 3, in accordance with one embodiment of the present disclosure. FIG. 5 depicts a magnified cutaway view of the improved drain installation 300 of FIG. 4, in accordance with one embodiment of the present disclosure.

As shown in FIGS. 3-5, the improved drain installation 300 may include a plumbing trap 312. In an embodiment, the plumbing trap 312 may be an integral U-shaped trap, although in other embodiments, it may be an S- or J-shaped trap. In an embodiment, an adapter 302 may be removably or permanently connected to a first end of the plumbing trap 312 at a first end of the adapter 302. In other embodiments, the adapter 302 may be internally, or integrally, formed and may be configured to be received within the first end of the plumbing trap 312 at a first end of the adapter 302. In other embodiments, an adapter may not be required. A drain outlet (not shown) may be removably or permanently connected to a second end of the plumbing trap 312 and the drain outlet may be connected to the main sewer line (also not shown). The drain outlet, the plumbing trap 312, and/or the adapter 302 may be permanently connected to each other with a plumbing cement or adhesive or may be removably connected to each other through a friction-fit type of engagement seal.

The improved drain installation 300 may further comprise a removable drain pipe 306, which may be connected to a first end of the plumbing trap 312 at a first end of the removable drain pipe 306.

The improved drain installation 300 may further comprise a sleeve 304 received around the removable drain pipe 306 and may extend to approximately an end of the removable drain pipe 306. Both the removable drain pipe 306 and the sleeve 304 may extend above a slab level of a flooring surface, requiring the removable drain pipe 306 to be cut to size before a fixture 308 may be attached to the end of the removable drain pipe 306. In an embodiment, the fixture 308 may be a floor drain or a shower drain. In an embodiment, the sleeve 304 may be a disposable sleeve or a reusable sleeve.

In some embodiments, an adapter 302 may be received between the plumbing trap 312 and the removable drain pipe 306. In such embodiments, the plumbing trap 312 may be received within a first end of the adapter 302 and the removable drain pipe 306 may be received within a second end of the adapter 302. A washer 314 may be received between the removable drain pipe 306 and the adapter 302 at the second end of the adapter 302 and may provide a seal between the removable drain pipe 306 and the adapter 302 such that gases and liquids cannot escape between the two. The first end of the removable drain pipe 306 may further comprise an angled end 322.

The adapter 302 may be shaped with a first diameter at its first end and a second, larger diameter at its second end connected by an angled transition 324 between the two. The first diameter at the first end may be sized and shaped to fit within the first end of the plumbing trap 312. The second diameter at the second end may be sized and shaped to receive the removable drain pipe 306. When inserted into the adapter 302, the angled first end 322 of the removable drain pipe 306 may interact with, but not pass beyond, the angled transition 324 of the adapter 302. The second end of the adapter 302 may further comprise an enclosed circumferential shoulder 316 operable to receive the washer 314 within the shoulder. The shoulder 316 may be sized and shaped to mate with the washer 314 and may include a circumferential lower lip 318 operable to engage with an inner circumferential shoulder 320 of the washer 314.

In FIGS. 3-5, the fixture 308 depicted is a floor drain. When installing a floor drain, unlike when installing a toilet or a sink, the removable drain pipe 306 is cut below the flooring surface so that the floor drain can sit flush with the flooring surface, allowing the water to drain. With a floor drain, a pre-form 310 may be used and received around the sleeve 304 and the removable drain pipe 306. The pre-form 310 may be shaped to correspond to the shape of the desired floor drain fixture 308.

During installation, both a plumber and a flooring specialist may be needed to properly install the improved drain installation 300. The plumber may first connect the plumbing trap 312 to the main drain outlet (not shown) that is connected to the sewer main (also not shown) below the flooring slab level. Next, the plumber may insert the washer 314 into the shoulder 316 of the adapter 302, or the washer 314 may be pre-installed into the shoulder 316, and connect the adapter 302 to the first end of the plumbing trap 312. The adapter 302 is operable to be inserted into the first end of the plumbing trap 312 at the first end of the adapter 302. Next, the plumber may connect the removable drain pipe 306 to the second end of the adapter 302. In an embodiment, the shoulder 316 may be received in the adapter 302 or in the integrally-formed P-shaped trap. The removable drain pipe 306 is operable to be inserted into the second end of the adapter 302, creating a seal between the removable drain pipe 306 and the adapter 302 at the washer 314. If an adapter is not desired, the plumber may connect the removable drain pipe 306 to the first end of the plumbing trap 312. The shoulder 316 and the washer 314 may be integrally formed at the first end of the plumbing trap 312. Once the removable drain pipe 306 has been connected to either the plumbing trap 312 or the adapter 302, the plumber may slide the sleeve 304 over the removable drain pipe 306. The sleeve 304 may be slid downwardly and proximate to the plumbing trap 312 or the adapter 302. If the fixture 308 being installed is a floor drain, the plumber may then slide the pre-form 310 over both the sleeve 304 and the removable drain pipe 306. The pre-form 310 may be slid downwardly so that an upper edge of the pre-form 310 is approximately level with the eventual height of the flooring slab level. Once the sub-floor plumbing is complete, the plumber may transition the project to the flooring specialist.

Next the flooring specialist may build the floor above the sub-floor and around the sleeve 304 and the removable drain pipe 306. The flooring specialist may start with a concrete or wood sub-floor (not shown) and then build a finished flooring surface (also not shown) above the sub-floor. The finished flooring surface may be made from tile, wood, finished concrete, or the like and may be various thicknesses based on the chosen finished flooring surface. The sub-floor and the finished flooring surface may extend entirely around the sleeve 304. Once the flooring is complete, the flooring specialist may finish the installation of the plumbing fixture 308 or may transition the project back to the plumber to finish installation of the plumbing fixture 308.

In the improved installation process, the flooring specialist or the plumber does not need to alter the finished flooring surface in any way in order to cut the removable drain pipe 306 to the desired height. Unlike the prior art methods, which required the flooring specialist or the plumber to chisel the flooring surface or to guestimate the desired height of the drain pipe, the current installation process allows the flooring specialist or the plumber to precisely cut the removable drain pipe 306 to the desired height without needing to chisel the sub-floor.

In order to finish installation of the plumbing fixture 308 in the improved installation process, either the flooring specialist or the plumber can mark the desired height of the removable drain pipe 306 or measure the distance from the end of the removable drain pipe 306 to the finished flooring surface. Next, either the flooring specialist or the plumber can remove the removable drain pipe 306 from the plumbing trap 312 or the adapter 302, while leaving the sleeve 304 in place relative to the sub-floor and the finished flooring surface. The sleeve 304 acts as an insulator between the removable drain pipe 306 and the sub-floor and the finished flooring surface and eliminates the traditional adhesive interaction that would be present between concrete and a traditional drain pipe. The sleeve 304 can be made from cardboard, wax paper, plastic, or any other insulating material.

Once the removable drain pipe 306 is removed partly or entirely from the sleeve 304 and the removable drain pipe 306 is cut to the proper length, while the sleeve 304 maintains and secures the aperture to allow the removable drain pipe 306 to be re-inserted through the sleeve 304.

After cutting the removable drain pipe 306 to the proper length, either the flooring specialist or the plumber may re-insert the removable drain pipe 306 through the sleeve 304 and into either the plumbing trap 312 or the adapter 302.

If an adapter is desired, the removable drain pipe 306 may be inserted into the sleeve 304 until the angled end 322 of removable drain pipe 306 interacts with the angled transition 324 of the adapter 302. Once re-inserted, the washer 314 again creates a seal between the adapter 302 and the removable drain pipe 306. During both removal and re-insertion of the removable drain pipe 306, the washer 314 may move within the shoulder 316 of the adapter 302, but if present, the circumferential lip 318 and circumferential shoulder 320 arrangement prevent the washer 314 from being removed from the shoulder 316.

Before the removable drain pipe 306 is re-inserted into the plumbing trap 312 and a proper seal is created, the flooring specialist may remove the sleeve 304 from between the sub-floor and finished flooring surface. If the fixture being installed is a floor drain, the pre-form 310 may also be removed, leaving an opening the same size and shape as the desired floor drain.

Once the removable drain pipe 306 has been cut to the desired length, and re-inserted into the trap 312, the flooring specialist can install the desired plumbing fixture 308. The plumbing fixture 308 may create a seal between the end of the removable drain pipe 306 and the finished flooring surface, or the plumber may create a seal (or additional seal) with caulk or another similar sealing material.

FIG. 6 depicts a cutaway view of an improved drain installation 400, in accordance with one embodiment of the present disclosure. Like the drain installation depicted in FIGS. 3-5, the improved drain installation 400 may include a plumbing trap 412. In an embodiment, the plumbing trap 412 may be an integral U-shaped trap, although in other embodiments, it may be an S- or J-shaped trap. A T-shaped adapter 402 may be connected to a first end of the plumbing trap 412 and may be configured to be received within the first end of the plumbing trap 412 at a first end of the T-shaped adapter 402. The T-shaped adapter 402 allows two plumbing fixtures to be installed in close proximity to each other, such as a floor drain and a sink in a bathroom, and connect to a single plumbing trap 412. An outlet pipe (not shown) may be connected to a second end of the plumbing trap 412 and the outlet pipe may be connected to the main sewer line (also not shown).

The improved drain installation 400 may further comprise a removable drain pipe 406a connected to a second end of the T-shaped adapter 402. The removable drain pipe 406a may be configured to be received within a shoulder formed in the second end of the T-shaped adapter 402. Washers 414a may be received between the removable drain pipe 406a and the T-shaped adapter 402 at the second end of the T-shaped adapter 402 and may provide a seal between the removable drain pipe 406a and the T-shaped adapter 402 such that gases and liquids cannot escape between the two.

The improved drain installation 400 may further comprise a secondary inlet pipe 406b connected to a third end of the T-shaped adapter 402. The secondary inlet pipe 406b may be configured to be received within a shoulder formed in the third end of the T-shaped adapter 402. Washer 414b may be received between the secondary inlet pipe 406b and the T-shaped adapter 402 at the third end of the T-shaped adapter 402 and may provide a seal between the secondary inlet pipe 406b and the T-shaped adapter 402 such that gases and liquids cannot escape between the two.

The improved drain installation 400 may further comprise one or more sleeves (not shown) received around the removable drain pipe 406a and may extend from proximate to the second and third ends of the T-shaped adapter 402 to approximately ends of the removable drain pipe 406a. The removable drain pipe 406a and the sleeve may extend above a slab level of a flooring surface, requiring the removable drain pipe 406a to be cut to size before fixtures may be attached to the end of the removable drain pipe 406a. In an embodiment, the fixtures may be floor drains, shower drains, or a combination thereof. The method of installing the improved drain installation 400 is similar to that described above in relation to the installation of the improved drain installation 300.

FIG. 7 depicts a cutaway view of the improved drain installation 300 of FIG. 3, in accordance with one embodiment of the present disclosure. As shown in FIG. 7, the removable drain pipe 306 may be encircled by the sleeve 304, but may further comprise an end cap 702. The end cap 702 may be placed on the open second end of the removable drain pipe 306 and may cap the removable drain pipe 306 so that gases and liquids do not escape into the room.

FIG. 8A depicts a perspective view of a first pre-form 310a of the improved drain installation of FIG. 3, in accordance with one embodiment of the present disclosure. FIG. 8B depicts a perspective view of a second pre-form 310b of the improved drain installation of FIG. 3, in accordance with one embodiment of the present disclosure. The pre-forms 310a, 310b may be sized and shaped to fit a desired floor drain and may be round, square, tapered, etc. The pre-forms 310a, 310b may advantageously prevent concrete from falling within the drain pipe and into the plumbing trap during installation.

FIG. 9 depicts an perspective view of an improved drain installation 900, in accordance with one embodiment of the present disclosure. In an embodiment, a first end of a drain pipe 902 may be connected to a first end of a plumbing trap 904 and a drain pre-form 906 may be received around a second end of the drain pipe 902. The first end of the drain pipe 902 may be cemented into the plumbing trap 904, while the drain pre-form 906 may be received around the second end of the drain pipe 902 and is operable to slide up and down the length of the drain pipe 902. In addition, the drain pre-form 906 is operable to be removed from the second end of the drain pipe 902.

In an embodiment, the drain pipe 902 may be cut to a desired length so that a floor drain 908 sits below a finished flooring level, and may be cut on-site or may be pre-cut to raise the drain pre-form 906 to a desired height above the plumbing trap 904. A plumber may slide the drain pre-form 906 downwardly around the drain pipe 902 to an approximate height of a finished flooring surface. The drain pre-form 906 may be sized and shaped to fit a desired floor drain and may be round, square, tapered, etc. The pre-form 906 may advantageously prevent concrete from falling within the drain pipe and into the plumbing trap during installation.

In operation, after the plumber installs the sub-floor plumbing—i.e., the drain pipe 902, the plumbing trap 904, and the drain pre-form 906—and the concrete slab has been poured around the sub-floor plumbing, a flooring specialist may install the finished flooring surface above the concrete slab and finish the installation of the drain. After the finished flooring surface has been laid to a desired height, which is preferably slightly above an upper surface of the drain pre-form 906, the flooring specialist may remove the drain pre-form 906 from the second end of the drain pipe 902 and cut the drain pipe 902 to a desired length. In order to cut the drain pipe 902 to a desired length after the finished flooring surface is installed, a specialty tool, such as a PVC wire saw, may be needed to cut the drain pipe 902 without damaging the finished flooring surface or the drain pipe 902. After cutting the drain pipe 902 to the desired length, the flooring specialist may cement the floor drain 908 into the second end of the drain pipe 902 so that an upper surface of the floor drain 908 may be flush, or slightly below, a surface of the finished flooring surface.

FIG. 10 depicts a perspective view of an exemplary pre-form 1000 for drain installation, whereas FIGS. 11, 12, and 13 depict a top view, a bottom view, and a side view of the pre-form 1000, respectively. Pre-form 1000 may refer to any pre-form described herein, including pre-form 310, pre-form 310a, pre-form 310b, and/or pre-form 906.

The pre-form 1000 may generally include a cap portion 1002, a bottom portion 1004, and an outer portion 1006. As shown in FIG. 10, the cap portion 1002 may include a circular piece that extends upward (e.g., substantially vertically) from the bottom portion 1004. In some embodiments, the cap portion 1002 may be substantially cylindrical. Alternatively, side walls of the cap portion 1002 that extend upward from the bottom portion 1004 may be angled and/or slanted. For example, the cap portion 1002 may be wider at its base (e.g., at a proximal end adjacently coupled to, substantially flush with, and/or on a plane parallel to the bottom portion 1004) than at its top (e.g., at a distal end that is positioned a distance away from the bottom surface). As shown in FIGS. 10-12, the top of the cap portion 1002 may include a substantially flat and solid circular surface. One or more raised supports 1008 may be disposed on an outside (e.g., top) surface of the top of the cap portion 1002 to ensure structural integrity of the cap portion 1002.

The base (e.g., the proximal end) of the cap portion 1002 may be coupled to the bottom portion 1004 of the pre-form 1000. In some embodiments, the cap portion 1002 may be detachably coupled to inner edges of the bottom portion 1004 via a perforated seam 1010. When force is applied to the pre-form 1000 during installation as described below, the cap portion 1002 may separate from the bottom portion 1004.

The bottom portion 1004 may include a substantially flat and solid square surface. The bottom portion 1004 may also include a variety of other shapes such as a rectangle, a circle, and/or the like so as to conform to a shape of a drain. One or more raised supports 1012 may be disposed on a top surface of the bottom portion 1004 to ensure structural integrity of the bottom portion 1004.

Outer edges of the bottom portion 1004 may be coupled to the outer portion 1006 of the pre-form 1000. The outer portion 1006 may include one or more substantially flat and solid surfaces (e.g., walls) that extend upwardly from the outer edges of the bottom portion 1004. In some embodiments, the outer portion 1006 may extend substantially vertically from the outer edges of the bottom portion 1004. In other embodiments, and as shown in FIG. 13, the outer portion 1006 may extend upwardly from the outer edges of the bottom portion 1004 at an angle so that a perimeter of the outer portion 1006 at a bottom end (e.g., at the outer edges of the bottom portion 1004) is smaller than a perimeter of the outer portion 1006 at a top end (e.g., at the end extended a distance away from the bottom portion 1004).

The pre-form 1000 may be manufactured from PVC, ABS, or any other rigid material. In some embodiments, the pre-form 1000 may be made from a single plastic mold. For example, each of the cap portion 1002, the bottom portion 1004, and the outer portion 1006 may be cast from a common mold and/or during a common plastic injection process. Alternatively, one or more of the cap portion 1002, the bottom portion 1004, and the outer portion 1006 may be cast from different molds.

The pre-form 1000 may be used when installing a plumbing system. For example, during installation of a subfloor plumbing system, the pre-form 1000 may be placed on top of an upwardly-extending drain pipe (not pictured). In some embodiments, the cap portion 1002 of the pre-form 1000 may be placed on top of the upwardly-extending drain pipe so that a top end of the drain pipe is received within the interior of the cap portion 1002 (e.g., the underside of the cap portion 1002). In this manner, the cap portion 1002 of the pre-form 1000 may cover an opening of the drain pipe so as to prevent unwanted debris or concrete mixture from entering the drain pipe opening during the pouring of concrete and/or drain pipe installation. The pre-form 1000 may rest on the top of the drain pipe until the concrete subfloor has been poured.

While the concrete subfloor is being poured and while the poured concrete subfloor is still wet (e.g., before the poured concrete subfloor has settled), the cap portion 1002 may be separated from the bottom portion 1004 of the pre-form 1000. For example, a plumber (e.g., a worker, a drain pipe installer, a concrete pourer, and/or the like) may apply a downward force on the outer portion 1006 of the pre-form 1000, thereby breaking the perforated seam 1010 between the cap portion 1002 and the bottom portion 1004.

Once the perforated seam 1010 is broken and the cap portion 1002 is separated from the bottom portion 1004 (as well as the outer portion 1006), the remaining portions (e.g., the bottom portion 1004 and the outer portion 1006) of the pre-form 1000 may be slid down around the outside surface the upwardly-extending drain pipe until it is resting in the wet concrete subfloor. As the remaining portions of the pre-form 1000 are slid down, the cap portion 1002 may remain positioned atop the upwardly-extending drain pipe to prevent unwanted debris from entering the drain pipe opening.

The remaining portions of the pre-form 1000 resting in the wet concrete of the poured subfloor may be pressed down into the wet concrete. For example, a plumber may apply downward force on the bottom portion 1004 and/or the outer portion 1006 so that the remaining portions of the pre-form 1000 are at least partially inserted into the wet concrete subfloor. In some embodiments, the remaining portions of the pre-form 1000 may be inserted into the wet concrete subfloor until the wet concrete subfloor surpasses and/or is substantially even (e.g., level) with a marker on an outside surface of the outer portion 1006.

Once inserted into the wet concrete subfloor, the remaining portions of the pre-form 1000 may displace a desired amount of wet concrete immediately surrounding the drain pipe so as to allow sufficient room for cutting the upwardly-extending drain pipe and installing a floor drain. For example, the bottom portion 1004 may downwardly displace wet concrete within an area defined by a perimeter of the outer portion 1006. By displacing the concrete subfloor using the remaining portions of the pre-form 1000, the drain pipe may be cut at a location below a finished floor level (e.g., at a location below a top edge of the pre-form 1000 and/or at a location below the concrete subfloor). In some embodiments, a top edge of the outer portion 1006 and/or another marker on an outside surface of the outer portion 1006 may be used as a marker for how deep into the concrete the pre-form is to be inserted as well as a marker for where the drain pipe is to be cut.

After the concrete subfloor has settled and is dry, the cap portion 1002 may be removed from the top of the drain pipe so that the drain pipe may be cut to a desired height and/or length. Additionally, the remaining portions of the pre-form 1000 may be removed from the concrete subfloor so that the drain pipe may be cut and/or so that a floor drain may be installed. Once the drain pipe is cut, a floor drain may be installed into the concrete subfloor and on a top end (e.g., at the opening) of the drain pipe.

As disclosed herein, the plumbing traps, removable drain pipes, and/or pre-forms may be constructed from PVC, ABS, cast iron, brass, copper, or any other material suitable for plumbing pipes. Similarly, the adapter and T-shaped adapter may be constructed from PVC, ABS, cast iron, brass, copper, or any other material suitable for plumbing pipe adapters. The washers may be constructed from plastic, foam, or any other material suitable to provide a seal between the removable drain pipes and the adapters. As discussed previously, the sleeve may be constructed from cardboard, wax paper, plastic, or any other non-adhesive material suitable to permit the removable drain pipe not to adhere to the sub-floor concrete and to allow movement of the removable drain pipes relative to the flooring. The cap may be constructed from PVC, ABS, cast iron, brass, copper, or any other material suitable for capping a plumbing pipe. Each of the components described herein may be sized and shaped to meet the plumbing needs of each individual plumbing fixture installation.

It should be appreciated that the breadth and scope of the invention(s) is not limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. Moreover, the above advantages and features are provided in described embodiments, but shall not limit the application of the claims to processes and structures accomplishing any or all of the above advantages.

Additionally, the section headings herein are provided for consistency with the suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” the claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered as a characterization of the invention(s) set forth in the claims found herein. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty claimed in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims associated with this disclosure, and the claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of the specification, but should not be constrained by the headings set forth herein.

Claims

1. A method of installing a drain fixture, the method comprising:

installing a sub-floor plumbing system comprising an upwardly extending drain pipe;

positioning a pre-form on a top end of the drain pipe, wherein the pre-form comprises: a cap portion that substantially covers an opening of the drain pipe; a bottom portion detachedly coupled to the cap portion; and an outer portion coupled to and upwardly extending from the bottom portion;

building a concrete flooring surface proximate to the drain pipe;

applying a downward force to the pre-form so as to cause the cap portion to detach from the bottom portion;

sliding the pre-form down the length of the drain pipe until the bottom portion is at least partially inserted into the concrete flooring surface proximate to the drain pipe while the concrete flooring surface is wet, wherein the cap portion remains positioned on the top end of the drain pipe;

removing the pre-form after the concrete flooring surface sets;

cutting the drain pipe to a desired length, thereby resulting in a shortened drain pipe; and

installing a drain on a top end of the shortened drain pipe.

2. The method of claim 1, wherein the cap portion, the bottom portion, and the outer portion are cast using a common injection mold.

3. The method of claim 1, wherein sliding the bottom portion of the pre-form down the length of the drain pipe until the bottom portion is at least partially inserted into the concrete flooring surface comprises:

displacing an amount of concrete proximate to the drain pipe, wherein the amount of displaced concrete is defined by dimensions of at least one of the bottom portion and the outer portion

4. The method of claim 1, wherein building the concrete flooring surface comprises:

pouring concrete proximate to the drain pipe and evenly spreading the concrete above the drain pipe area.

5. The method of claim 1, wherein applying a downward force to the pre-form comprises applying a downward force to a top edge of the outer portion.

6. The method of claim 1, wherein the bottom portion is inserted into the concrete flooring surface until the concrete flooring surface is substantially level with a marker disposed on an outside surface of the outer portion.

7. The method of claim 1, wherein the top end of the drain pipe is received within an interior of the cap portion when the pre-form is positioned on the top end of the drain pipe.

8. The method of claim 1, wherein the cap portion is detachedly coupled to the bottom portion via a perforated seam that is broken when the downward force is applied to the pre-form.

9. The method of claim 1, wherein the bottom portion comprises an aperture through which the drain pipe passes when the bottom portion of the pre-form is slid down the length of the drain pipe.

10. The method of claim 1, wherein the drain pipe is cut so that the height of the shortened drain pipe does not extend above a level of the finished flooring surface.

11. The method of claim 1, wherein installing the drain comprises:

coupling the drain to the top end of the shortened drain pipe; and

sealing a space between the drain and the concrete flooring surface.

12. A pre-form for drain installation comprising:

a cap portion defining an interior for receiving a top end of an upwardly extending drain pipe;

a bottom portion detachedly coupled to the cap portion and comprising an aperture through which the drain pipe passes so as to enable the bottom portion to slide along the length of the drain pipe; and

an outer portion coupled to and extending upwardly from the bottom portion so as to define a perimeter for displacing concrete proximate to the drain pipe when inserted into a wet concrete flooring surface.

13. The pre-form of claim 12, wherein the cap portion substantially covers an opening of the drain pipe.

14. The pre-form of claim 12, wherein the cap portion is detachedly coupled to the bottom portion via a perforated seam that is broken when a downward force is applied to the bottom portion or the outer portion.

15. The pre-form of claim 12, wherein the cap portion remains positioned on the top end of the drain pipe.

16. The pre-form of claim 12, wherein the outer portion comprises a marker for at least one of:

identifying a height to which a pre-form is to be inserted into a wet concrete surface; and

identifying a height to which the drain pipe is to be cut.

17. The pre-form of claim 12, wherein an outer edge of the bottom portion is coupled to a bottom edge of the outer portion, and wherein the bottom edge of the outer portion defines a perimeter that is smaller than a perimeter defined by a top edge of the outer portion.

18. The pre-form of claim 12, wherein the cap portion, the bottom portion, and the outer portion are cast as one piece using a common injection mold.

19. The method of claim 1, wherein building a concrete flooring surface proximate to the drain pipe comprises building a thin set mortar surface proximate to the drain pipe.

20. The pre-form of claim 12, wherein the concrete includes thin set mortar.