AU2005100344B4 - Slot-Drain System - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR AN INNOVATION PATENT

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Aachen Industries Pty Ltd [ABN 90 101 146 883] 6 Berry Street, Rosebery, NSW, 2018 CORBETT, Francis Andrew Paul A Grant and Associates PO Box 7460, Fisher, ACT, 2611 INVENTION TITLE: Slot- ASSOCIATED APPLICATION: Drain System Application No. 2004 902511 Application Date: 13 May 2004 The invention is described in the following statement:- TITLE: Slot-Drain System TECHNICAL FIELD This invention relates to slot-drains, slot-drain systems and draining methods for use with the floors of bathrooms and other wet areas in buildings.

BACKGROUND TO THE INVENTION Floor drains in bathrooms and other wet areas typically consist of a drain pipe set into the floor with a metal or plastic grill fitted into the open top of the pipe so as to be flush with the floor surface. While the grill prevents large articles from entering the drain, it tends to collect hair and dust, and is difficult to keep clean.

OBJECTIVES OF THE INVENTION An objective of the invention is to provide a floor-drain system that will be less unsightly that the conventional floor-drain. Other objectives and benefits will become apparent from the following description.

OUTLINE OF THE INVENTION From one aspect, this invention comprises a slot-drain system or assembly suitable for use in draining the floor of a wet area, such as a bathroom, that is finished with a cladding or covering layer. The slot-drain system basically comprises a tubular outlet member having a top adapted to supporting the floor cladding when the member is mounted there-below, at least one side-inlet socket or spigot in the side of the outlet member at or near the top thereof and at least one open-top elongate channel member adapted to connect with the socket or spigot; the channel member being adapted to form a slot-like drain inlet for water immediately below the level of the floor cladding and to convey water flowing therein into the outlet member via the side spigot or socket.

It is convenient for the outlet member to be normally arranged with its axis vertical and to have a bottom opening that is adapted for connection to the sewer via a conventional S-bend water trap. Since sewer piping is normally of circular section, the bottom opening of the outlet member is conveniently also of circular section and proportioned so that it can be readily coupled to a standard sewer pipe. The top of the outlet member is conveniently open, defining a top rim. Since the outlet member will normally be mounted against or adjacent the wall to be furnished with the slot-drain, one side of the outlet member may be linear or flattened and the side sockets or spigots may be aligned with that side. In that event, the intermediate portion of the outlet member between the top of the outlet member and the bottom outlet opening will be shaped to interface or join the flattened top section with the circular bottom section. The outlet member may be funnel-like in that it may have an open top of larger dimension than its outlet.

The outlet member can be adapted to support the floor cladding in various ways.

If the cladding is thick and strong, like quarry tiles, the adaptation need only be by way of suitably dimensioned upper rim and walls. It is preferable however that the top of the outlet member be closed or closeable to support the cladding or covering layer and to assist in excluding grout, glue and the like from the outlet when installing the floor cladding.

A cover-plate supported from or near the rim of outlet member may be used to close the top of the outlet member. Such cover plates can be made to close off the top of the outlet member so as to entirely exclude the entry of the grout or glue used to fix the cladding. The cover plate can be thin and lightweight and simply located by small protrusions on the inside surface of the outlet so that the top of the cover-plate is flush with the top of the rim. Such cover-plates will be suitable where the cladding is robust (as in heavy tiles), or where the cladding is light (as in vinyl sheeting) but the outlet is located in a place that will not be subject to any significant load, like the corner area between the floor and one or more walls.

Additionally or alternatively, an open-topped outlet member can be adapted to support the floor cladding by the use of a tubular plug-like insert that fits in the bottom opening and is supported thereby, the plug being smaller than the interior of the outlet member so that water can flow between it and the wall of the outlet.

Thus, the plug insert can be located within the outlet member both vertically and horizontally to ensure that its upper surface is level with the top rim of the outlet member. Preferably, the plug insert has side slots or holes to permit the water to exit from the bottom opening of the outlet member by flowing radially inwards through such slots or holes, which may be formed as a grid or covered by a mesh to exclude large solid items from passing through the outlet member.

The fully or partially closed top of the outlet member allows a removable tile or polished stone cladding piece to be glued to the closure so that it is accurately located with respect to the surrounding cladding material. Thus, the closure and attached tile or stone can be removed to allow the interior of the outlet member to be inspected or cleaned and then accurately replaced in the same position. The accuracy of location can be such that the joint between the removable piece of lo stone and its neighbors is nearly invisible.

Additionally or alternatively, the outlet member may be adapted to support the cladding by having a fixed or integral closed or partially closed top surface. If, as is preferred, the bottom of the outlet member is smaller than the top, integral molding of the top closure may be difficult or expensive, so a welded or glued top by be employed.

The inlet spigots or sockets that receive the side channels will usually be two in number, opposed and arranged in-line and off-center on one side (here called the 'back') of the outlet member so that the outlet member can be mounted adjacent or against a wall and the channels can extend along the corner between the wall and the floor in both directions. Alternatively, but less desirably, only one inlet spigot or socket may be provided so that the outlet member can be mounted in the corner between two walls and the floor. Another alternative is to employ three or more spigots or sockets so that a radiating set of side channels may be used in a floor that is dished with the outlet member in the center (under the cladding) and with radiating slots in the cladding feeding the channels. Alternatively, again, the side inlet sockets or spigots may be arranged at right angles, and two sides of the outlet member may be flattened and of angular form so that it is adapted for location in the corner between two adjacent walls and the floor, with the channels running along the base of the adjacent walls.

As already mentioned, the side channels are open-topped and the spigots or the sockets in the outlet member are preferably arranged so that the channels feed into the back of the outlet member with their top edges at the level of the outlet member rim; that is, just below the floor cladding. Each channel preferably tapers in depth, getting deeper toward the outlet member; that is, getting deeper further down-stream. This means that the top edges of the channel sides can be arranged substantially horizontal at the level of the underside of the floor cladding while the bottom of the channel slopes toward the outlet member, ensuring drainage of the channel. Preferably, the channel is of rectangular section, making it easier to lay in place, but channels of semicircular, triangular or other sections are also envisaged. It is also preferable that the downstream end of the channel lo feeding the outlet member fits within a socket in the outlet member that is shaped to receive it, ensuring the smooth flow of water into the outlet member.

Multiple lengths of channel may be coupled together using molded unions, each channel preferably tapering as described above. If desired, the channels can be carried around a wall corner with the use of elbow moldings. End stops, caps or similar moldings may also be used to close off the shallow end of a terminal channel in a neat manner.

As already indicated, it is envisaged that the floor cladding will be laid over the top of the outlet member and that it will overlap the channel edges, leaving only a dark narrow slot visible. When this slot is located at the junction between a wall and the floor, the floor drain will be essentially invisible, yet it will be highly effective, provided the floor is appropriately pitched.

DESCRIPTION OF EXAMPLES Having portrayed the nature of the present invention, a particular example will now be described with reference to the accompanying drawings. However, those skilled in the art will appreciate that many variations and modifications can be made to the example without departing from the scope of the invention as defined in the claims at the end of this specification. In the accompanying drawings: Figure 1 is an exploded view showing the components of the slot-drain system of the chosen example.

Figure 2 is a sectional elevation of a first version of an installed system, taken through the centerline of the outlet member and showing the floor cladding in the form of floor tiles.

Figure 3 is a sectional elevation like that of Figure 2, except that a second version of the system is shown.

Figure 4 is a perspective view from above of the outlet member molding of the systems of Figures 1 3.

Figure 5 is a perspective view from below of the outlet member molding of Figure 4.

Figures 6 and 7 are front and side elevations of the outlet member molding of Figures 4 and The complete system 10 and components of the chosen example will now be introduced and described with reference to Figure 1. The central component is a vertically-arranged hollow tubular funnel-like outlet member 12 that is of generally circular section, except for the rear of the top portion that comprises an integral rectangular-form transverse channel 14 which has a rectangular-section socket or spigot 16 protruding laterally from each side. [Reference should also be made to Figures 4 7 which depict the outlet member in more detail.] Sockets 16 are integrally joined by a common flat back wall 18, the top edges of sockets 16 and wall 18 being substantially coplanar with the top 20 of a rim wall 22 that encompasses the front of outlet member 12. Rim wall 22 is of substantially semicircular form and, together with back wall 18 effectively surrounds a circular and downwardly and inwardly tapering top bore 24 of outlet member 12. Top bore 24 terminates in a narrow internal flange 26, below which is formed a bottom bore or bottom opening 28 that connects with a standard drain pipe 30 (indicated in broken lines).

One end 31 of a length of rectangular section open-topped channel 32 is fitted into left hand socket 16 and, preferably, glued in place, the free end 34 of channel 32 being closed by a rectangular end-cap 36 that is also glued in place. A similar channel 38 is fitted and glued into the right hand socket 16 but its free end is fixed in a rectangular-section right-angled open-topped elbow 40 into which one end 43 of a second channel 44 is fixed, the free end 46 of channel 44 being closed by a rectangular end cap 48. Channels 32, 38 and 44 are preferably of tapering depth but of constant width, the channels becoming deeper toward outlet member 12 so that water entering them will flow evenly into the outlet member.

Two alternative means of supporting floor cladding (not shown in Figure 1) on outlet member 12 are depicted in Figure 1. One is a flat cover plate 50 that is a neat fit in the top of rim wall 22 of outlet member 12, resting on a plurality of small protrusions 52 on the inside of wall 22 so that the top surface of plate 50 will be substantially flush with rim 20. Accordingly, the front face 54 of plate 50 is semicircular, like rim 20, but the back face 56 of plate 50 is straight so that, when fitted in place, it will line up with the front walls of spigots or sockets 16 (rather than extend to back wall 18). Cover plate 50 is relatively thin and weak and is, therefore, intended to close off the top of outlet member 12 against ingress of grout or glue during the laying of the floor cladding, rather than to bear any substantial floor loading. Accordingly, cover plate 50 is intended for use in where relatively strong cladding is used that can be supported on rim 20 and span the top opening of outlet member 12.

The second alternative for adapting outlet member 12 to support the floor cladding is a cylindrical hollow plug 60 that has a flat top 62 and sturdy walls 64 that are formed with two large opposed side openings 66. If desired, side openings 66 can be in the form of a molded grid or pattern of smaller holes to act as a screen to prevent large solid objects from passing through outlet member 12 into sewer The bottom of walls 64 taper inwards so that they will not foul the sides of opening 24 of outlet member 12 but rest on internal flange 26. When plug 60 is fitted into outlet member 12, resting on flange 26, its top surface 62 is substantially level with rim 20. Being robust, plug 60 can support weak or flexible tiles or vinyl floor coverings. However, the principal use of plug 60 is where one wishes to be able to inspect and/or clear the outlet member by removing a tile or a portion of stone floor-cladding. By gluing the tile to the top of plug 60, plug 60 then serves to O accurately align the removable piece of cladding with other parts of the floor. This N alternative is illustrated in Figure 3, to be described below.

Figure 2 is a sectional view of outlet member 12 fitted in place in a cast concrete floor 70 cladded with tiles 72 laid on grouting 74, outlet member 12 being set so that its rim 20 is flush with the floor level 76. Cover plate 50 can be fitted in place (as shown) while the floor is cast so as to reduce the ingress of concrete into Ooutlet member 12. In this variant, floor-tile grouting 74 is carried right over cover plate 50 and the edge tile 72a is laid on top to leave a drain slot 80 between it and lo the bottom wall tile 82, which is laid on wall grouting 84.

Thus, in the variant shown in Figure 2, it is assumed that floor tile 72a is unlikely to crack if stepped on due to deflection of cover plate 50 and (ii) there will be no need to access outlet member 12 in order to clear blockages. The latter assumption is safe because the thin slot 80 and narrow drain channels 38 ensure that articles or debris big enough to block the outlet member 12 (or drain 30) are excluded.

Figure 3 is a sectional elevation of the second variant of the chosen example where the same reference numerals have been used for the same elements as shown in Figure 2. The principal differences in this variant are that: hollow plug is substituted for cover plate 50, stone floor and wall cladding 72b and 82b are used in place of tiles, a removable piece of floor cladding 72c is cut to fit over outlet member 12 and water-impermeable membranes 90 and 92 are used beneath and behind the floor and stone cladding 72a and 82a in accordance with good practice.

To support the floor cladding 72b a bedding layer of compressed sand and cement 94 is applied over the top 76 of the cast concrete floor and a floor membrane 90 is laid down so as to overlap slightly with rim 20 of outlet member 12 and to overlap slightly with the edge of channel 38 (though the latter is not shown) so that any leakage of water through cracks or joints in the stone will be carried into the outlet member or channel. A layer of cement grout or glue 74 is then applied on top of floor membrane 90 before the stone cladding 72b is laid.

Essentially the same procedure is followed for the wall cladding 82b, where membrane 92 is first fixed in place so as to overlap edge of channel 38 and edge 18 of outlet member 12, and then glue or grout 84 is applied before the wall stone is set in place.

A piece 72c of stone floor cladding is fixed onto the top of plug 60 with a layer of glue 74 so that piece 72c and plug 60 can be removed as one piece to access or clear the outlet 12 and/or drain pipe 30. Because plug 60 is so precisely and firmly located in outlet member 12 (both vertically and laterally), cladding piece 72c is also accurately located and can be cut to effectively hide the parting lines with the parent stone 72b.

It will be appreciated that many changes can be made to the examples without departing from the scope of the invention as set out in the following claims.