CA2554544A1 - Self-cleaning flooring with flushing fluid means and drain system - Google Patents

Abstract

A self-cleaning flooring system is provided that includes at least one module.
The module comprises a drain pan, a plurality of discharge ports, and at least one side wall. The drain pan may have a ramp and a drain outlet. The ramp may slope downward towards the drain outlet. The discharge ports may be disposed about a periphery of the drain pan and may be directed towards the drain outlet to direct flushing fluid towards the drain outlet. The side wall may circumscribe a portion of the periphery of the drain pan and include a hollow passage and at least one fluid inlet. The fluid inlet may be in fluid communication with the hollow passage for delivering flushing fluid to the discharge ports.

Description

SELF-CLEANING FLOORING SYSTEM
CROSS-REFERENCE fO REL,ATED APPLICATIONS
This application is a continuation-in-part of co-pending United States Application Serial No. 10/282,393. filed October 29, 2002, and co-pending;
~l.S.
Application Serial No. 11107,814, filed March 8, 2005, the CIltrre COIltentS
Of which are hereby incorporated by reference.
STATEMENT RE: FEDERALLY SI'ONSORI~D RI:SI~ARCH/DI;VI:LOPIV1EN'l~
Not Applicable IiAC.'I~GROLTND
The present invention relates generallyflooringprotection and, to more particularly, to self cleaning flooringhavingmodules which a system are interconnectable to horizontally adjacent to a continuous modules form flooring system for catching waste products in a variety of applications and industries including, but not limited to, laundry facilities and food preparation facilities. The flooring system of the present invention rnay also be formed as ~ a permanrnl installation that is cast in a concrete floor using removable male mold inserts chat duplicate the shape of a drain pan and over which floor grids may be installed for supporting personnel standing thereupon.
Advantageously, the flooring system of the present invention is adapted i«r use in dairies, meat processing plants, stables, poultry operations, IIlaChllrC 5170pS, clean assembly rooms, printing facilities, and food processing plants.
Furthermore, the flooring system of the present invention may be used in transition areas in animal processing applicatior;s. For eramplc, the flooring system of the present invention may be used between a feed yard and dairy milking stations wherein hooves of livestock passing over the flooring system could be sprayed prior to entering the dairy milking station such that undesirable residue (e.g., manure) may be washed ti~om the livestock hooves and into tl:e flooring system for later retrieval as fertiliser.
Irl lllal7y industries, CIeaI111neSS OI~ certain facilities and COOmS 1S
Crit1Ci11. For examplz, in the. food preparation industry. sanitation and cleanliness in the kitchen is a major concern. The kitchen flooring in restaurants, hotels, institutions, and commercial food vending facilities in general is subject to frequent spillage from waste products. Such waste products may be in the form of spilled liquids, semi-solids, and small solids and may include grease, oil, water, and an infinite variety of food products. Spilled waste products may create a sanitation hazard as a hot kitchen is a natural breeding ground for harmful bacteria that may be caught in tile grunt, atld alo.und pipes, drains or other kitchen fixtures. F3ecause of the immovable t:ature oi~
such kitchen fixtures, cleanliness is dillicult if not impossible to maintain.
Stringent health codes in most states require that kitchens in commercial food vending facilities f 0 mceivt= daily cleaning.
Daily cleaning of walls, counter tops, appliances and floors involves a great deal of hand labor consuming a considerable amount of time. In addition, the waste products may create a health hazard in that spilled food products are often wet or sticky, creating a high risk that kitchen personnel may be injured in a fall.
IS Furthermore, spilled grease or oil crcat~s a tire safety ha-rard requiring the cessation of all operations in the kitchen until the grease or oil is removed from the floor. As may be expected, shutting down all kitchen operations in a restaurant or hotel may result in a significant LOSS Uf revenue. In addition, current cleaning methods of Facilities such as commercial kitchens may entail the temporary removal and/or 20 dismantling of certain equipment and flooring systems followed by lengthy washing with water. As may be appreciated, smh clcanin~ 111CthOdS rCSUILS 1(1 the use of large quantities of water which may increase water conservation issues in certain locales.
There is currently known in the prior art flooring systems that are configured to address sanitation and safety concerns. One prior art device comprises a washable 25 floor for collecting waste. 'fhe clcvice provides a grid or mesh on which a person may stand, the grid mounted above a sub-floor onto which waste falls. 'The sub-floor is downward sloping towards a drain outlca. Flushing means arc provided for flushing the fluid waste down the Stlb-flUOr towards the drain outlet. The grid is pivotably movable between a horizontal position and a vertical position and is removable to 30 facilitate maintenance. Although the device addresses a Few safety and sanitation issues mentioned above in that it provides a disposal means for fluid waste, the device lacks installation flexibility in that it must be custom lifted to a particular floor configuration. In addition, the size of the grids and sub-floor are such that these components are too heavy and too large to be individually washed, either by hand or by mechanical means, such as in a commercial dishwasher.
Another prior art device provides a suppol-ting surface for personnel standing thereupon. 'I-he device allows water or fluid to flow through the supporting surlace S al7d underneath a modular flooring member. The de~'ICC IIlCludeS 1 SCI'leS
Of cross channels forming a gridwork of fluid pads which permit water to flow underneath the modular flooring. I-Iowever, a major drawback to the device is that a large portion of the subsurface of the flooring Il7embC1' is in direct contact with the moist support floor.
Althouf;h this device addresses some safety concerns in that it provides a non-slip surface upon which personnel may stand, the device is subject io the problems of mildew and degradation of the subfloor arising from captured water. Ful-thermore, the device is not conf ibured to be easily washable by hand or by mechanical means.
Finally, the above-mentioned devices require the use of lar~~e amounts of water for thorough cleaning thereof.
I S As can be seen, there exists a need in the art for a flooring system for catching waste products that also provides a non-slip surface upon which personnel may stand to reduce the risk of injury from slipping. Furthermore, there exists a need in the art for a flooring system that is self cleaning such that ~vastc products may be flushed toward a drain outlet for subsequent disposal. Additionally, there exists' a need in the art for a flooring system that is light weight and of small si-rc such that it is removable for easy clcaninf; by hand or with cleaning equipment such as a comtncrcial dishwasher as may be found 111 a e0I71l11e1'Clal kltCl7e11.
Also, there exists a need in the art for a flooring system that is modular such that individual modules may be interconnected to cover a desired ,,~.rea in a variety of aplolications and industries including, but not limited to, laundry facilities and food preparation facilities such as a cooking line in a con imercial kitchen.
Hinally, there exists a need in the art for a flooring; system that may be permanently molded into a concrete floor usinb removable male mold inserts that duplicate the shape of a drain pan and over which t7oor grids may be installed for suppol-ting personnel standing thereupon. Such a flooring system may he used in various industries including, but not limited to, dairies, stables and meat hroccsslng plants.

BRIEF SUMMARY
'rhe present invention specifically addresses and alleviates the above referenced deficiencies associated with Mooring systems. More particularly, the present invention is an improved self-cleaning flooring system for catching waste products. In one embodiment, the flooring system is modular and is configured such that it may be cleaned using cleaning eCILlIplnetlt that tS typical of the industry wherein the, Flooring system is installed. For example, if the flooring system is installed in a commercial kitchen, the flooring system is adapicd io he cleaned LlSirl~
C0111117e1'Clal dishwashing equipment. In another embodiment, the flooring system may be cast-in-place into a concrete substrate: using foam inserts such that upon curing of the concrete, removal of the foam inserts, lrlStL111atiU11 Ol~ plumbing, and laying oC door grids, a durable flooring system is provided.
In accordance with an embodiment of the present Invention, there is provided a self cleaning flooring SyStt:rll for catching waste products. The i7ooring system has at !cast one module comprised of a drain pan and a floor grid. 1'hc drain pan includes a pair of ramps and a drain channel centrally located betty ~cen the ramps.
'hhe drain pan may include a pair of side walls and a pair of end walls. The ramps are disposed on opposite sides of~ the drain channel and slope downwardly towards the drain ChannCl. The dra rn channel extends L~ctwecn the end walls and slopes duwnwardly from one end of the drain pan toward an opposite cod of the drain pan toward a drain outlet. The side and end walls collectively form a periphery of the drain pan and extend upwardly from the ramps and drain channel to enclose the drain pan. The side:
walls and/or ramps have at least one, and, preferably, a plurality of dischar~~e mechanisms such as discharge ports and/or spray nozzles fur releasing flushing Iluid onto the ramp such that waste products that fail onto the ramps arc washed toward the d1'alll channel.
'The floor grid is configured to support personnel and/or animals standing upon or moving thereacross while permrttlng waste products to pass thcrcthrough.
The side wall may include a hollow passage having a fluid inlet whereby flushing fluid may be delivered to the discharge ports. 'the fluid inlet of adjacent ones of the modules also allows for the flushing fluid to flow thercbetwecn. flie end most one of the modules may be connectable to the flushing fluid source. 'fhe fluid inlet 171ay bC
CUI7neCted to a fluid supply wherein flushing fluid is delivered to the hollow passage. An overflow passage may be provided near the drain channel for allowing the flow of flushing fluid and/or liquid waste products between adjacent modules. The floor grid may comprise a plurality of abutting Boor l;rids disposed parallel to one another.
The floor Lrids arc sized such that the length of the lllOdtlle lnatchCS Lhe Conlblned ICIl~tl1 O1_ the 5 abutting floor grids. The module may include a plurality of dowels with the side walls havinb complimentary apertures sized for receiving the dowels for interconnecting the modules.
'hhe desired number of drain pans are assembled horizontally and joined using dowels or other suitable means. 'hhc fluid inlets are connected to the flushing fluid source. During use, the flushing fluid Mows from the fluid inlets into the drain pans.
The flushing fluid may be provided on a periodic basis through the use of a timed control valve. Alternately, the flushing fluid may be manually provided as desired when the accumulation of waste products on the ramps reaches a critical level.
Additionally, a thermal sensor may operate to provide ihc flushing fluid to the fluid inlet in the case of a fire. The flushing fluid may be il the form of water fru111 a tap water source, and is discharged out of the discharge ports. The flushing;
fluid may he pressurized and the flushing fluid may include additives such as degreasers tcl facilitate breakdown of certain food substances.
Waste products that fall through the floor grid arc washed by the Ilushny fluid down the ramps toward the drain channel. Once in the drain channel, the flushing Iluid then washes the waste products toward the drain outlet. Removable strainer trays ma~~ be used over the dI'aln Cl?anl2el to prevent waste products ft-om entering floc drain channel. Drain baskets may be installed over the drain outlet to prevent wash products from washing down the ;train outlet. Floor grids may be installed over the drain pan to support personnel standing or working above the drain pans. 'hhc Moor _ grids are preferably sized and configured to prevent waste products o(~ a predetermined size from enterin~~ the drain pan.
BRIEI' DI:SCRIP1~ION OF 7~1II~ DRAWINGS
These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description anti drawings, 111 Wh1C11 tike numbers refer to like parts throughout, and in which:

Figure I is a perspective view of a first embodiment of a flooring system illustrating the connective relationship of horizontally adjacent modules that may make up the flooring system;
Figure 2 is an exploded perspective view of the flooring system of Fib. I
illustrating a module and the relationship of a drain pall and floor gri~Is that make up the Illodllle;
Figure 3 is a longitudinal sectional view of the module taken along line 3-3 of Fig. 1 illustrating ramps sloping downwardly toward a drain channel;
Figure 4 is an enlarged paI-tial Sectional vices of the module taken from Fig.

illustrating the COIIneCtlVe rtlat10I15hIp of a spray 17o7zlc disposed within a siclc wail of the module; .
I=figure 5 is a tI'aIISVGrSC SeCtIUllal view of tile InOdtdc of the (first embodiment taken along line 5-5 of Fig. I illustrating.: the drain channel sloping downvvardly toward a drain outlet;
I 5 Figure G is a perspective view of a second embodiment of the flooring system illustrating the connective relationship of floor grids and horizontally adjacent Clralil pan sections that make up a drain pan assembly;
Pi~:ure 7 is an exploded pcrsp cctivc view of the flooring system of~ Fig. G
illustrating the cotlnective relationship of a first and a second ramp section with a channel section that make up the drain pan section of the second embodiment;
figure 8 is a block diagram of a pressure lank and timer connected to the modules of the present invention;
Figure 9 is a perspective view of the flooring system wherein the drain pan includes a drain channel that is singly-sloped toward the drain outlet located at one end of the drain pan;
Figure lU is a cross-sectional view of the module taken along Illle 10-IU of Figure 9 and illustrating a the drain pan installed in a concrete substrate wherein the drain pan includes a perimeter flange formed about a periphery of the drain pan to support the drain pan;
Figure 11 is a top view of the i110C1u1C shUWl1 111 Figure 9 illustrating an arrangement ofthe spray nOLllf:S IIlStalled in the ramps;
Figure 12 is a sizie view of the module of Figure 9 illustrating the drain chanclc) sloping from one end of the drain pan to the other toward the drain outlet;

Figure 13 is a partial cross sectional view of the I7ooring system in a further embodiment wherein the drain pan is cast-in-place into a concrete substrate and illustrating a manifold disposed above one of the ramps and to which spray nozzles may be fluidly connected;
Figure 14 is a schematic diagram of a plumbing system in an embodiment w~hercin the plumbing system is interconnected to a series of Spray IlUZZIeS
11151a11ed in a single section of the flooring system; and Figure 1 ~ is a schematic diagram of a plumbing system in another embodiment wherein the plumbin f; system is interconnected to a dual section of the flooring system.
DETAILED DISCRIPTIUN
'I he present invention will now be described in particular with reference to the accompanying drawings. Figures 1 and 2 show a module 1? of the first preferred embodiment of a flooring SySIetll 10 for catching waste products. Figure I is a prospective view of the first elnbodllllei7t of the flooring system 10 illustrating the connective relationships of horizontally adjacently disposed modules 12 that make up the flooring system 10 illustrating the module I2 alld the relationship of a drain pan 14 and floor grids 24 Thai make up the 177Odtlle 12 ol~the first embodtlncnt:
?0 AlthouLh Figures I and 2 show the module 12 as having three of the floor grids '_'~4 disposed upon the drain pan 14, it is contemplated that the nu>dulc 1? may include at least one or any number of Moor grids ?4. Preferably, such floor grids ?~.
will coIlcctivcly be sufficient to cover the drain pan 14. 'hhe drain pan 14 is shown in the f cures as having a gcncraily rectangular shape. F lowevcr, the drriin pan 1 ~1 may l7e COIlfI~';llred iu any nulllbeC Of ShapCS alld SI7eS. Preferably, the dra111 pan 14 IS
configured such that the modules 12 may be interconnected to one another in a horizontally aligned manner. Each one of the drain pans 14 may have a square shape with the floor grid 24 being sized and configured completncntary to the shape of the drain pan 14.
30 Referring still to Figures l and ?, as can be seen, the drain pan 14 includes a drain channel 40, a pair of ramps 1 G, a pair of side wails 26 and a pair of end walls ~+?.
The ramps 1 G are diaposed on opposite sides of the drain channel 40 along the length of the drain channel ~i0. As can be seen in Ivigurc ?, the ramps 16 are oriented to g slope dow nwardIy along a dll'CCti011 llldiGated by the arrows (l.e., towards the dram channel 40). The drain channel 40 is interposed between the side walls 2G and extends between the end walls 42.
~fhe drain channel 40 itself may he configured to slope downwardly from one end of the drain pan 14 to the opposite elld of the drain pan 14 toward a drain outlet 18. 'hhc drain outlet 18 may be connected to a drainage or sewage system of the facility within which the flooring system 10 is installed. A removable drain basket 78 may be provided with tl~e flooring system IO and may be installed over the drain outlet 18 for preventing SOlIdS Or SCr711SUlld waste products oi~ a predetermined size from entering the drain outlet 18. Alternatively. or in conjunction vaith the drain basket 78, an elongate. flat filtering mesh 62 may be provided along the length of the drain channel 40, (shov<~n only in Fi~;uro 2), to provide an additional treasure of filtering of~waste products.
As shown in Figure 2, the drain channel 40 may slope downwardly toward the centralized drain outlet 18 positioned midway along the drain channel 40. Itl tilts regard, the drain channel 40 may have two separate sloping surfaces that slope toward one another toward the centrally located drain chatxnel 40. However, the configuration of the drain pan 14 wherein the drain channel 40 has only the single sloping surface is preferred. In this configuration, the drain channel 40 slopes downwardly from one of the end walls 42 of the drain pan 14 toward the other one of the end walls 42 of the drain pan 14.
'the drain outlet 18 is preferably positioned adjacent to one of the end walls 42. The end walls 42 as well as the side walls 26 extend upwardly from the ramps 16 to enclose the drain pan 14. Likewise. the end walls 42 also extend upwardly from the drain channel 40 to provide enclosure to the drain pan 14. Provided in each one of the ramps 16 may be a plurality of discharge ports 22 whiclu arc specifically configured for releasing or spraying flushing fluid onto the ramps 16 such that masts products arc washed down the ramp 1 G toward the drain channel 40.
As was earlier mentioned, floor grids 24 may be mounted atop each one of the drain pans 14. In order to enhance removability and to facilitate washing and cleaning of the floor grids 24, the floor grids 24 may be provided 111 reduced sizes (i.e., widths) such that a plurality of flog ~~rids 24 disposed in abuttin~~
relationship to one another are required for covering one of the drain pans 14. For example, as is shown in Figure 2, three of the floor grids 24 are required in order to completely cover the drain pan 14.
The floor grids 24 are preferably appropriately sired and confilurcd to support personnel, animals or other loads placed thereupon while pernllttulg waste products to S pass therethrough. The floor grids 24 are supported at the periphery of the drain pan 14 and may be specifically mounted on the side walls 26 such as along the grid support notches 82 extending along the length of each one ol~the side walls 26. In this regard, the floor grids 24 extend across the ramps 1 G and the drain channel 4() and may be supported by the side walls 26. Optionally. grid support notches 82 may also be provided along each one of the end walls ~2 such that the end most otlcs of the door grids ?4 may be supported by the grid support ncltches 82 along the end walls 42. .
Although the figures show the drain pan 1 ~ having side walls 26, it is contemplated that the module 12 may be comprised of a drain pan 14 having a single l5 one of the ramps 16 that extends or w raps around the drain pan l~. In such an arrangement, the ramp 1G defines the drain pan periphery '?0 front where it slopes dUWnWfll'dly toward the: drain cllanllcl =I0. Alternatively, the drain pan 14 may be configured SLiCh that the ramp 16 slopes downwardly tclwards the drain outlet 18. 'l~hc drain pan periphery 20 may have a pl!lrality of the discharge ports 22 spaced therealong for spraying flushing fluid onto the ramp 1 G.
In one embodiment. each one of the SIdC w.llls 2C) nlaY' include a hollow passage 28 formed thercalong and through which !lashing Fluid may tlcn~~. A
fluid inlet 30 may be provided in at least one of the end vralls 42 as well as in the side walls 26 and is configured to provide ilushinc fluid to the ramps 1 G via the hollow passa'~cs 28. Alternatively, Ill elnbUdll11e11tS that UI711L the 11U11Uw pilSSa~;C 28, tllC f111s11111~,T lllild . may enter the Iluid inlet 30 and may be proviclcd directly to the ramps 1 G.
I Iowcvcr, tile fluid inlet 30 !nay provide a conduit tllrough which a manifold 9~ may pass and which carries flushing fluid to tile distharbe pol-ts 22 or spray nozzles 32.
its can he seen in Figure 1, the self=cleaning flooring system 10 of the present invention may be comprised of a plurality of the modules 12 with each one of the nludules 12 being configured to be connectable to one another in horizontal alignment. Interconnectahlity of the modules 12 is facilitated through the usi; of mechanical fixtures such as, for example, a dowel 3C and aperture 38 systcrn wherein dowels 36 are provided in one of the modules l2 and into which may be received by apertures 38 formed in an adjacent one of the modules 1?.
However, it will be appreciated that the module 12 may be interconnected to one another through a variety of attachment mechanisms and is not limited by the 5 specific embodiments or configurations shown and disclosed hcrcwithin. AS
shown in Figure 2, the module 12 may include at least one strainer tray 74 which may be configured to extend along the length of the drain channel 40 and w111ch May be mounted above the drain channel 40. The strainer tray 74 is preferably configured to fit within the drain channel 40 and is operative to prevent waste products of a 10 predetermined size from entering the drain channel 40.
As can be seen in Figure 2. the strainer tray 74 extends along the length of the drain channel 40 and is specifically a daptcd to complement the dual sloped surface of the drain channel 4O. In this regard, the strainer tray 74 has a middle t111ckncsS which is larger than the thickness at the free ends ofthc strainer tray 74. 'The strainer trav 74 may additionally include a grate 76 that acts as a filtering IT1CC17a111SIT1 to prevent waste products from passing into the drain channel 40. For configurations wherein the drain channel 40 is configured as ~l slllglc 5101)lllg surface sloping downwardly toward the drain outlet 18 at an end of the drain pan 14, the strainer channel is prefcrabiy configured complimentary thereto. More shecitically, the strainer tray 74 is preferably configured to be thicker at one end than at an opposite end such that the grate 76 mounted atop the strainer tray 74 is disposed in general horizontal orientation when installed in the drain channel 40.
Turning now to Figures 9-12, shown is a self-cleaning flooring system 10 of the present IIIVeI7t1011 In a17 f:mbOdIIl7tilt t)lat may be installed on a substrate 88 such as ?5 a concrete substrate 88. ~ls can be seen in Figure 10. the drain pan 14 may be installed on a setting bed of dry packed concrete although the drain pan 14 may be installed on a substrate 88 of any composition. The periphery of the drain pan 14 may include a perimeter flange 80 extending thcrearound which acts as a ledge upon which the drain pan 14 may be supported. The perimeter Mange 80 extends laterally outwardly from side walls 26 of the drain pan 14. Preferably, the perimeter flange 80 is installed so as to be even with floor level 8G. More specifically, the perimeter flange 80 of the drain part 14 is preferably installed to be: Much with an upper surface of the floor covering 8~ at the floor Level 8G such as tluor tile or other .floor coverings 84.
As can be seen in Figure 10, the. ramps 16 of the drain pan 14 may be installed on the substrate 88 such as the concrete substrate 88 which may, in turn, be installed over a base surface such as a grading 90 of earthen or soil. 'rhc setting bed then may be in turn Laid atop the concrete substrate 88 and may be comprised of dry packed concrete. The floor covering 84 such as floor tile may be then, in turn, installed over the setting bed. The perimeter flange 80 may be installed over the setting bed and is preferably level with the floor level 8G.
1'he embodiment of the flouring system I O shown lIl Figures 9-12 Is slmllar in configuration to that which is shown in Figures 1-2 and which is described above.
More specifically, the drain pan I4 as shown in Figures 9-12 may bc: comprised of a pair of opposing ramps 16 that slope duwnwarclly toward a drain channel 40.
However, it is contemplated that each one of the modules 12 may be comprised of a drain pan 1'~ llavlll~ Ollly 0110 I'alllp IG with a drain outlet 18 disposed IIl a corner of the drain pan 14. The ramp 1 C may slope downwardly toward the drain outlet 18.
I-lowcvcr, it is believed that the COnil~lll'atiOtl ShO~~l~l1 lil Figures 1 and 2 and Figures 9-l2 is preferable wherein the drain pan 14 is comprised of a pair of ramps 16 disposed an opposite sides of the drain channel 40. The drain channel 40, as described abate, is sloped dowmvardly toward the drain outlet 18 which is located adjacent to the end wall 42.
Referring still to Figure 10, as can be seen, the opening formed in the substrate 88 and setting bed is sized to be slightly larger than the drain pan 14. More specifically, the opening includes areas into which plumbing (such as a manifold 94 for carrying flushing fluid), may be installed after curing of the concrete.
Once the _ plumbing is installed, the drain pan 14 can be installed with portions of the ramp 1 G
resting upon the substrate 88.
The drain pan 14 nlay then be supported at the periphery thereof by installation of the dry packed concrete which forms the final setting bed. In tilts regard, the dry packed concrete falls voids underneath the side wall 26 and perimeter flange 80. The drain pan 14 nlay be chcclccd for lcvelness to ensure proper fltnCttOllltlg aIlC1 tl0'lh'Ing Of the f~LiS11111~ tlLlld dlll'lllg Operat1011 Of' the ~00rtI1~ Sy'Ste111 I U. It is contemplated that reinforcement bar may be provided to assist in leveling of the drain pan 14 prior to installation of the setting bed.
It is contemplated that the drain pan 14 may be installed in multi-Iloor buildings wherein steel decking may be utilized as the substrate 88. In this regard. the S dram pan 14 can be accommodated with appropriate cutouts to allow f itmcnt and support of the drain pan 14 on the steel decking. 'I~hc flooring system 10 of the present invention may be installed similar to the method for installinb a floor sink or tl'ULtgh. Mounting straps may be secured to the decking prior to pouring of concrete which, in turn, occurs prior to installation of the drain pan 14. As was carlic;r lU mentioned, it is preferable that thv drain pan 14 is checked for levclness prior to pouring or curing of the concrete.
Following installation of the manifold 94 and installation of the drain pan 14.
the appropriate numhcr of discharge ports 22 such as spray nozzles 32 may be fluidly ' connected to the: manifold 94 such that llushing fluid passing through the manifold 94 15 maybe discharged out of the spray nozzles 32. As can be seen in Figure 1 1, three of the spray nozzles 3? are provided on opposite sides of the drain pan 14 and are extended thl'OLlgl1 the ramp 16 portions tliercof. The spray 110zz1eS 3? muv be threadably connected to the manifold 94. .Although three of the spray nozzles 32 are shown on each side of the drain pan 14. any number may be provided.
2U Furthermore, although the spray nozzles 3? are shown in Figure 1 U as extending through a crease or slope-change in the ramp 16, it is contemplated that the spray nozzles 32 may be installed anywhere along the ramps 16. I=urthermorc, although the ramp 16 shown in Fibure 10 has a doubly-sloped surface, it is contemplated that the ramp 1 G may be provided with a singly sloped surface 25 extending ti-om the side wall ?6 down to the drain channel 4U.
Additionally, it is contemplated that the ramp 16 may be curved or have a multiply angled or sloped surface. IIowevcr, it is believed that the sinblc or doubly sloped surface is preferred in order to enhance the w~ashin~ of the waste products down the ramp 1 G
toward ihc drain channel 40.
30 Referring to higurc 3, shown is a longitudinal sectional V1CVJ Ol~ llle 111Udllle 12 taken along line 3-3 of Figure 1 and illustrating ramps 16 sloping downwardly toward the drain channel 40. ~5 can be seen in l~ igurc 3, the fluid inlets 3U allow fur the flushing fluid to flow between adjacent ones of the modules 12 with the endmost module 12 in the flooring system 10 being connected to the flushing fluid source. The fluid inlet 30 may be connected to a fluid supply wherein the fluid is delivered to the hollow passages 28 or to the drain pan I4 via a manifold 94 or other similar plumbing system 96.
The flushing fluid may contain additives such as degreasers which may be injected into the fluid. The fluid Illav be water based or may be comprised of alternative liquids. For cxanlple, degreaser may be provided or injected into the fluid in order to break down grease that is deposited on the ramp 16. As can be seen in Figure 3, the~fluid inlets 30 may be disposed on the side walls 26 and; or the end walls 42 and may be concentric with the hulloes passage 28 to allow fluid to flow thcrebetweetl. If the hollow passages 28 are not included, the fluid inlets 30 may be COIlIICCtCd t0 a IllfLtllfOld 94 OI' ut11C1' plLlillblill~ CO1111eCt1011 1V11CI'e117 the dlschargc pol-ts 22 and/or spray nozzles 32 receive flushing fluid thcrchrom.
Turning now to Figure 4, shown is an enlarged partial sectional view of the I S module 12 taken from Figure 3 alld Illustrating the connective relatlonshlp Of the spray nozzle 32 w'lthln the side wall 2ci. /~S waS Car11C1' illent1011CC1, tile Splay I70'7.I1C
32 or diSCIIaI'gC pol-t 22 play be disposed above or adjacent to the ramps I
C. The discharge ports 22 may be internally threaded for receiving the spray nozzles which may be included in the module I2. 'hhe spray llOZZles 32 may lie discharged fi'on l the flushing fluid at an elevated pressure level in order to improve the CffCCtIVenCSS wltll w'111Ch the waste products may be washed down tile ramps 1 G
toward the drain channel 40. The spray nozzles 32 may be conventional spray nozzles 32 or alternatively, play be watcr,jcts that arv integrated into the manifold 94 without separate spray nozzles 32.
Regarding operation of the discharge ports 22 and/or spray 110ZZ1eS 32, it is contemplated that flushing fluid may be discharged therefrom via manual or automatic activation. For automatic activation, a timer 70 may be included with the flooring system 10 in order to periodically or at scheduled intervals, release flushing fluid into the ramps 1 G. Fut-thermorc, the spray nozzles 32 and/or discharge ports 22 3U may be activated via a thermal sensor such that flushing fluid play bC
discharged in case of (ire in the facility in which the flooring system 10 is installed.
Referring still to Figure 3, the drain pan-14 may include at least one overflow passage 48 pro~cilnate the drain channel 40 to allow for the flow of flushing fluid and/or liduid 4vaste products between adjacent ones of the modules 12. The overflow passages 48 may be formed in the end walls 42 of the drain pan 14 and may be collocated such that when the: modules 12 are connected together, the. passage is provided via the overflow passages 48.
As is shown in Figure 4, the drain pan 14 supports the floor grid 24 via a grid support notch 82 that is formed in the Side w all 26. As is Shown 117 Figure 4, the grid support notch 82 is created via the formation of the hollow passage 28 which extends along the length of the side wall 2C. Alternatively, as is shown in the preferred embodiment in Figures 9-12, the grid suppol-t notch 82 is formed in the side wall 26 with the edge of the floor grid 24 resting along the grid support notch 82. A
lower peripheral edge of each one of the floor grids 24 is preferably chamfered or radius to provide a gap between the side: wall 2G and the floor grid 24 (i.e., the grid silphort notch 82) such that the floor grid 2~ doers not sharply hear against radius corners of the grid support notch 82. Furthermore. the lower peripheral edge may be chamicrcd or radius to provide a gap sclch that waste products may pass therebctween.
Referring to Figures 3-5, each one of the drain pans 14 may comprise or include parallel spaced rib members ~1G disposed along a length of the drain part 1~1 between the end walls 42. The parallel rib members 4G may be disposed widthwise under the ramps IG and drain channel ~0 for supporting the module I'' in an even fashion un the sub-floor such as a tile and grout sub-floor that is COn11110111f found in commercial kitchens and other vending establishments. Likewise, as was earlier mentioned, the flooring system 10 may be installed in a variety of applications and industries including, but not limited to, dairies, meat processing plants, poultry operations, and stables wherein the rib members 46 niay be utilized to support the drain pan 14 alld dr'alll ChaI117e1 ~0 in an even manner.
'hhe drain pan 14 ntay be formed of any suitable material including metallic and 11017-t77efa111C Illatc:I'lalS. IvOr IIlCtaIll(: IllatCI'lalS, it Is COIIteITlplated that the drain pan 14 would be formed of stainless steel or otherwise suitable metallic material that is resistant to corrosion and or deDradation due to the environmental effects.
I~or non metallic materials, it is contemplated that a polymeric material such as polyvinyl chloride (Pf3C) and/or polypropylene play be utilized.
Furthermore, Iiber~lass may be utiliaed. In lhls regard, it is contemplated that the drain pan 14 lna)' be formed of any material that is suitable and that is compatible with the elevated temperatures that the drain pan 14 may encounter during washing such as during washing in a commercial dishwasher. The drain pan 14 may be formed as a unitary structure by any method such as by injection molding. More specifically. it is contemplated that the side walls 26, end walls 42, drain chancel 40, 5 ramps 16 and rib members 46 as will as grid suppoc-t notcl7eS 8? and other features of the drain pan 14 may be formed via an injection molding process so that the drain pan 14. is formed as a single unitary structure.
Durinb fabrication, it is contemplated that all corners may be radiused in order Cf'.dllee the probabilities of stress cracking that may be lnduceCl by localized stresses lU in corners. 1'UrthCCI11U1'e, radiused corners facilitate cleaning of the drain pan 14 wherein waste products that may otherwise gather in nooks and crannies and otherwise hard-to-reach-corners, are more easily washed and cleaned. The lower floor grids 24 may be radiused to be complementary to any radii formed in the grid support nOLChes 82 above thf; SidC walls ~6(1. In Ihls manner, the floor grid 2~1 lwvcr 15 surface and substantially abutting contact with the side wall 26 and/or grid support notch 82.
Turning nosy to Figure 5, shown in ti transverse sectional view of the module 12 of the first embodiment taken along line 5-5 of Figure 1 and illustrating the drain channel 40 slopinf; duwl)wardly toward the drain outlet 18. In I'igtire 5, the rib 20 members 46 can be seen extending vertically downwardly from tIm ramp l6 lower surface. Discharge ports 22 can be seen disposed within the side wall 26 and extending along the length thereof. 'hhe discharge; pouts 2? ma~~ be evenly spaced between the ,end walls 42 although any spacing is contemplated for the discharge pol'IS 2~.
'rhe strainer tray 74 is shown disposed above or mounted within the drain channel 40 which extends from end wall 42 to end wall 42. ~1s was earlier mentioned, the strainer tray 74 includes a grate 76 which prevents the entry of'solid or semisolid waste products into the drain channel 40 which may otherwise; fall into the drain outlet 18 resulting in clocging thereof. As a final measure of protection, a removable drain basket 78 may be included in the drain outlet 18 and disposed thereovcr in order to prevent solid waste from falling into the drain outlet 18 and clogging dOWll stream fcatLll'es Such aS a grGaSe Trap.

In Figures 1-5 as well as in Figures lU and 13. the floor grids 24 are shown formed as an array of spaced parallel grid members 34 that are joined together with the transversely disposed spaced grid n1e171bers 34. 'The spacings of the grid members 34 is preferably such that passage of semisolid and liquid waste products is allowed while preventing passage of waste products of a predetermined size. ns was earlier mentioned, the floor grids 24 are sized and configured to span between the side walls 26 of the drain pan 14. Similar to tl:c materials used for forming the drain pan 14, the floor grids 24~may be formed Of hl~h stl'ellgth 111ate1'lal.
For caample, the floor l;rids 24 may be fabricated of fiberglass material as such material is lightweight to allow easy removal f or cleaning of the Mooring, system 10 as well as for cleaning of the floor grid 24 itself; as well as hibhly structurally sound in order LO sLlppol't the perSOIlIIeI wOrlCln~ atld standinb thereupon.
It will be understood that the floor grids 24 may be formccJ of any material and in any configuration sufficient to prevent passage of waste products of a predetermined size.
Furthermore. it is contemplated that the material used in fabricating the floor grids 24 is compatible with commercial cleaning cdulpment such as commercial dishwashers and therefore is capable of surviving elevated temperatures. 'fhe embodiment of tire floor system 10 may be of any size and shape. Ilowcver, it is contemplated that in order to facilitate cleaning of the modules 12, it is contemplated that the width of the drain pan 14 arid floor grid 24 is compatible with cleaning equipment.
Turning now to Figures 6 and 7. shown is a second embodiment of a self=
cleaning flooring system 1 U which, as was earlier mentioned, comprises at least one module l2, but preferably comprises a series of modules l2 joined end-to-end.
lJack one of the modules 12 comprises a drain pan section 6C which is itself comprised of a pair of first and second ramp sections ~0, 52, and a channel section 54 which is . disposed between the first and second ramp sections 50, 52. As shown in Figure 6 and 7, the first ramp section 5U is joined to the second ramp sCCtloll 52 which is interconnected to the channel section 54. The channel section 54 is preferably configured to removably interconnect the Iirst and second ramp sections 50, s2 together at a lower side portion 5i3 of each one Of the first and second ramp sections 50, 52.
As was mcntioncd'for the configuration in higures 1-5, the first and second ramp sections 50, 52 slope downwardly toward the channel section 54. '1"he module 12 shown in Figures 6 and 7 is also comprised of at least one discharge port 22 which is preferably mounted above or adjacent to the first and/or second ramp sections 50, 52 and which is operative to separate flushing fluid onto the first and second ramp suction S0, S2 such that waste products are washed down the first and second ramp sections 50, 52 toward the channel section 54 and then from the channel section 54 toward the drain outlet l 8.
The configuration of the flooring system 10 shown in Figures 6 and 7 is similar to that w'hlCh IS ShoWll atld deSCClbed above in Figures I-S except for the drain pan section f G being comprised of the l7rst and second ramp sections 50, 52 and channel section 54. Furthermore, the drain pan section 66 ShOwll 111 Figures C
and 7 may further comprise end plates 64 which may be disposed on extreme ends of rack one of the modules 12 after assembly Of ColISCCUtIVe ollC,S C)f 1hC drain pall SeCtlolls G6.
For example, as is shown in Figure 7, tile end plate 64 may be secured to an extreme end of one pair of drain pan sections 66 which are adjoined end-to-end.
Another one of the end plates 64 may be adjoined to an opposite end of the module i 2 which comprises two of the drain pan sections G6. >rach one of the drain pan sections 66 includes the channel section S4 which includes the drain outlet 18 at an end thereof. Preferably, the channel section 54 slopes downwardly toward the drain outlia 18 but is not necessarily so. For example, it is contemplated that the channel section 54 may be formed with no slope and may he horizontally formed.
Each one of the first and second ramp sections 50. 52 may include at least one rib member 46 which extends from the side wall 2G of the ramp 16 section towarc! the drain channel 40. The rib member 46 is disposed under the ramp 1 G section and is preferably configured to support the ramp I G sc;etion above a substrate 88.
~s can be 2S seen in Figure 7, the first ramp section SO is of a narrower width than the second ramp section 52 although the first and second ramp sections 50, 52 may be equally coal ibured.
A plurality of discharge ports 22 and/or spray nozzles 32 may be disposed along upper side portions SC of the first and second ramp sections 50, 52. At least one strainer tray 74 may be mounted above the channel section 54 and may be configured to prevent waste products of a predetermined sire from entering the drain channci 40.
Alternatively, a plurality of strainer trays 74 may be connected end-to-end and mounted above each one of the drain channels 40. Optionally, the strainer truly 74 tnay be omitted such that waste products of any size may be flushed down the drain outlet 18 and may pass into a holding tank.
Although the drain pan assembly (i8 and, more: specifically, drain pan sections GG of the second embodiment may he of any size and any shape, it is contemplated that the first ramp section 50 is sized to he compatible with commercially available cleaning equipment as well as tIIC SCCOIld ramp section 52 being likewise sized to facilitate cleaning. Accordingly, the floor grids 24 are preferably sized to be compatible with commercial cleaning equipment. In this regard, depending upon the method of cleaning, it is contemplated that the drain pan sections GG and, hen ce, the drain pan assemblies G8, may be formed at any size and any shape.
As can be seen in Figure 7, vertically extending grid supports 60 play be provided with the first and second ramp sections 50, 52 in order to suppol't the floor grids 24. For industries wllere a person may be standing on the floor grids 24 fi)r an extended period Of time, It 1S COlltenlplatCd that StICh '.?I'Id SuppOrlS GO
may be e1111C1' 1I1n1tCd OC all tOgCthl'.r 1'enlOVCd IIl 01'dCr t0 allow SOI11C ClCgrCC Of ilC~;n~ 111 LhC fll)Ol' brid 24 in order to enhance the comfort of personnel standing thereupon for extended periods ot~time. As can be seen, one of the drain pan sections G6 omits the use of the grid supports GO while the other one of drain pan sections GG which is joined end-to-end includes the floor grid support GO for exemplary purposes only.
Referring now io Figure I3, shown is the flooring system 10 in a further CI11170d1I11Cnt ~vllercin the drain pall 14 is formed or cast into a substrate 88 such as a concrete substrate 88. l~lore specifically, the flooring system 10 shown 111 Fil;urc 13 illustrates the drain pan I4 having the same or similar features as described above for t1 flooring systems 10 of Figures 1-5 <lnd 9-12. More specifically, the substrate 88 itself forms the shape of the drain pan 1-t wherein the substrate 88 itself includes a pair of ramps 1 G which slope downwardly toward a drain channel 40 w ~ith the drain channel 40 itself sloping downwardly toward the drain outlet 18. 1'he drain pall 14 defines the periphery thereof .with a perimeter flange 80 being formed around the drain pan 14 for suppol-cing the (loot grid ?4 on an upper surface of the substrate 88.
As shown in Figure 13, the flooring system 10 further includes a nlanili~ld 94 which may be extended along a portion of the drain pan 14 and which is formed within a corner of one of the ramps 1 G. T'hc manifold 94 extends along a portion of the ramp 1G and is disposed above the ramp 1G in order to provide flushing fluid to the ramp 16 for washing waste products down to the drain channel 40. The flooring system 10 further includes a spray nozzle 32 which may be fluidly connected to the manifold 94 and may be operative to spray flushing fluid down the ramp 16 toward the drain channel 40. However, it should be noted that the spray nozzle 32 nlay be omitted with apertures 38 instead being formed in the manifold 94 to form ports through which. flushing fluid may be discharged for spraying flushing fluid down the I'an7pS 1 ~.
~rlle CZSt CoIlCretC, syStCtll whlCll fortlls tile flooring system 10 Of the present invention may be developed for use in any of the above-mentioned applications and industries. For example, the cast concrete system may be used in dairies, tncat processing plants. stables and other facilities and applications that typically endure heavy wear due to contact with the heavy animals. Other applications where tllc cast concrete system for the flooring system 10 SIIUVVII Ii1 Figure 13 include poultry operations, emergency rooms, machine shops, clean rooms, printing facilities, food processing giants and other industrial operations. Furthermore, the flooring system 10 of the present invention may be used in transition areas in animal processing applications.
For example, the flooring systcnl 10 of the present invention may he used between a seed yard and dairy milking StattOllS. In this regard. the flooring system lU
may be installed in certain transition areas and may include an above-ground spray element that could be triggered by hooves of~ livestock passing over the flooring system 10. Once the spray element is triggered, fluid may be sprayed onto the livestock hooves v~~hile such livestock is entering the dairy milking station such that undesirable residue (e.g., manure) may he washed from the livestock hooves and into the flooring system l0 for later retrieval as fertilizer. It is contemplated that a triggering mechanism may be included with the flooring system 10 to activate the spray element. Such triggering mE;Challlsill Ill ay be COllflgul'ed as an 111f1'aI'Cd bf;anl that is triggered by the livestock hooves.
Regarding the first above-mentioned application for tile cast concrete system of the flooring system 10, it is contemplated that the manifold 94 and/or spray 110zzles 32 and/or discharge ports 22 that are typically used for washing flushing tluld down the ramps t G, may also bzr used for spraying animals hooves as the; cross over the flooring syStenl 10. In this manner, uwvanted sediments and manure from stockyards may be washed from the hooves of livestock to increase the hygiene and cleanliness of~the facility into which the flooring Sy5LC111 10 is installed.
As was earlier mentioned, in a dairy. it is contelnplatcd that the lloortnb system 10 may be configured to spray the hooves of dairy cows when brought into a 5 milking facility such as into a rotating milking system. Advantageously, the flooring system 10 as ShOwl1 111 Fiburc 13 is installed aS a C~ISt-ltl-pl~iCe s1'stCll7 w'hei'elll the dl°ain pan 14 itself is formed directly in the substrate 88 such as the concrete substrate 88. Ideally, the drain pan 14 is located in the area in which it is to be installed via location of the drain channel 40 flowing down towards the drain outlet I8.
10 Furthermore, it is contemplated that the floor srids 2=1 for such an application arc appropriately sized and COIIfIgjtII'cd to handle heavy loads imposed by large livestock such as cattle. In this regard, it is contemplated that the floor grids 24 have an increased thickness such as a two (2) inch thickness for increased load-bearing capacity. As shown in Fig. 13, floor ~~rid supports 60 may be included to provide 15 additional support against heavy loads.
As shown in Figure 13, the; drain pan 14 Inay be formed in the substrate 88 using; a removable insert which 1S COllflf~lll'Cd aS a 111a1e 111oId that duplicates the shape of the drain pan 14. Figure 13 represents one-half of the installation with the: other half being symmetrically formed about the vertical centerline. I-Iciwever, it is 20 contemplated that the installation of the drain pan may he asymmetrical. As was earlier mentioned, the male mold will ideafiy include the features described above for the drain pan 14 such as the side wall 26, grid support notch 82, ramps 16, and drain channel 40.
The removable insert may preferably be formed as a foam material which may be shaped as a single unitary piece of foam or may be shaped as a series of foam . inserts 92 which arc individual pieces that collectively define the drain pan 14 shape when installed prior to flooring; of the substrate 88 such as a concrete substrate 88.
Installation of the flooring system 10 is ilI:CUIl1p11S17ed by lllltlally Iay11l1JT out and locating the drain pan 14 with reference to the drain outlet 18 such as the drain channel 40 the drain pan 14 is roughly centered on the; drain outlet l 8.
The foam tray be placed in the shape of th c drain pan I4 after which the concrete may be poured underneath around the insert. Just prior to or after curing of the concrete, the foam insert 92 may be rclnovcd after which the concrete can proceed to final cure. As can be seen in Figure 13, a depression may be formed in the ramp 16 to receive the manifold 94 which may run lengthwise along the ramp 16. ~I~hc manifold 94 may be connected to the flushing fluid source and is operative to spray hushing fluid down the ramp 16. The ~~rid support notch 8~ is formed in the side wall 26 and is specifically shaped and confi';urcel to be complementary to the thickness of the floor grid 24 ibr support of the floor grid 2-l thereupon.
Referring now to Figures 14 and I S, shown therein is a schematic diagram illustrating a plumbing system 96 as may be connected to the flooring system 10 of the present invention. Figure 14 illustrates the plumbing system 96 Interconnected to a series of discharge ports 22 and!or spray nozzlea ~2 installed in a single section of the flooring system 10. As can be seen in hicure 14, the floOI'ln~ system 10 includes tw,:> modules 12 connected end-to-end with each module 12 including six discharge ports ?2 and/or spray nozzles 32. The spray nozzles 32 on one side of the flooring system 10 are connected in series. This schematic diagram of Figure I4 illustrates the 1 S proper assembly for flooring system 10 configurations having anywhere 11'0111 four to si;cteen spray nozzles 32.
Figure 1 S is a schematic diagram of the plumbing system 96 in a further embodiment wherein a pair of flooring systems 10 is interconnected to the 171lllllblllg system 96 in parallel. More specifically, the plumbing system 96 supplies flushing fluid to a first flooring system 10 and a second flooring system 10 illustrated ill Figure I S as being disposed above one another. As will be appreciated. the flooring system 10 shown in Figure 14 is similar to one of the pairs of flooring systems 10 illustrated in Figure 1 S. It is contemplated that the: flushing fluid is provided by a water supply line 100. Such water supply may be a cold water supply line 100 having a dian;cter of 2S about'/z inch in a standard supply line 100. IIowevcr, it is contemplated that a'/~ inch diameter water supply line 100 may be provided ~.viih the plutnbtng system 96.
Minimum static pressure for the water supply line 100 is preferably about fi fty-five PS1 although the water supply may be provided in any pressure level.
1-iowevcr, it is preferable that consistent water pressure be provided to the flooring system 10 and, thercibre, depending upon the number of spray nozzles i? and/or discharge ports 22 included within the flooring system 10, a complementary supply line 100 diameter and pressure level should be provided. Along these lines, it is contemplated that a pressure source may be included in the plumbing system 96 sllCh as a pressure tank 72 in order to add the appropriate amount of pressure to the flooring system 10 and plumbing system 96. liven further, the plumbing system 96 may include a pump in order to increase the pressure level of the flushing fluid supply.
Referring to figure 14, it can be seen that ihc flushing fluid may be provided via a supply line 100 which feeds into a shutoff valve 102 that may be activated under certain circumstances such as upon loss of power. Also included in the schematic diagram is a check valve 104 which may bi: interposed between the pressure tank 72 and the shutoff valve 102 to prevent back flow of hushing fluid. Downstream of the pressure tank 72, a solenoid-controlled-valve 106 may be included.
The valve may he controlled by a timer 70 or by a manual switch. ~I-he supply line 100 leading to the flooring system 10 may preferably he a'/~ inch diameter supply line 1UO in order to provide adequate flow of hushing fluid to the floorrng system 10.
Each one of the flooring systems 10 may include a Deader 98 disposed on one end thereof for connection to the plumbing system 96. As can be seen in Figure 14, each of the spray nozzles 32 on one of the sides of the flooring system 10 is prctcrabiy connect in series. A cap may be provided at the end of each one of the; series ol~
discharge pores 22 and/or spray nozzles 32.
Referring now to Figure 15. shown is the schematic diagram having a pair of the flooring Sl's1C111s 10 installed in parallel. 'hhe plumbing system ~ 96 provides flushing fluid, such as water, to the respective ones of the flooring systems 10. Tl~e cOTnpOnelllry of~ the schematic dragram shown 111 Figure 15 is similar to that descrihed and shown in Figure 14 above. I Iowcvcr, a pair of the solenoid-controlled-valves 106 are included at a split in the supply line 100. Notably, instead of connecting the discharge ports 22 and/or spray nozzles 32 in series, the SCI7elIlatlC diagram of Figure I S show an alternative arrangement wherein Lhree of the spray nozzles 32 are connected to another three of the spray nozzles 32 in parallel with one another. A cap may be provided at an end of~each one of the series of three spray nozzles 32.
Regarding drainage from the drain outlet 18, it is contemplated that a three inch diameter connection be utilized in order to connect a waste conduit of at least three inches in diameter to each one of the flooring systems 10. ,~ls was earlier mentioned. the drain outlet l8 may lead to a grease trap. Timers 70 alld solenords may optionally be further included in the flooring systems 10 and may be either manually or autonomously operated. It is contemplated that the timer 70 system may include a manual override in order to allow an operator additional control in the frequency of spraying of tile flushing fluid.
Regarding the pressure tank 72, it is contemplated that each pressure tank 72 may include the capability for contalnln g about si:c gallons of flushing fluid in order to produce about three to four gallons of flushing fluid that may be pressurized to about thirty to thirty-five I'SI, nn additional valve may be included with the pressure tank 72 in order to provide control over the operating pressure at which the pressure tank 72 operates. As was earlier mentioned, commercial degreasing agents and other additives may be injected into the plumbing system 96 supply line 100 as shown in Figures 14 and I S as required.
'hhe operation of the flooring system 10 will now be described with reference to Figures l-15. The flooring system 10 as shown in Figures I-2 may be installed initial by placing the drain pan 14 on the surface to which it is to be mounted. As was earlier mentioned, such surface rnay include a concrete flooring substrate 88 or a steel 1 S decking arrangement although various other configurations are concert lplatcd upon which the flooring systerlls 10 may be installed. The following connection of the plumbing system 96 as iilustratcd in (~igures 1~-I5, the flushing fluid may be provided to the pressure tank 72 and then to the SCI'les Of dlSCllar~C ports 22 and/or spray IlOZZIeS 32 upon activation of the p111r11bIllg syStf',111 9G.
Such activation may be autonomous via a timer 70 or via manual activation by the appropriate personnel. During use. waste products fall through the floor grids 24 and pass therethrough landing on tll~ ramps I G. At appropriate intervals or when Manually activated, flushing fluid is discharged onto the ramps 1 G washing the waste products dUwI1 to the strainer tray 7~ i f lncludcd. The grating of the strainer tra~~ 7~
prevents waste products of a predetermined size fl'0111 Cllter111g into the drain ch~lnrl~l ~0. The flushing fluid causes the waste products to fold toward tile drain outlet 18 wherein the addition of a drain basket 78 further prevents entering of such waste products into the drain outlet 18 and clogging of the grease trap.
For the drain pare assembly G8 modules I2 as show 11 in Figures 3-7, following interconnection of the channel section ~4 to the first and second ramp sections S0. 52 and SCCL1I'lng of the end plates 6~1 upon abutting connection of the drain pall sCCtlolls 6G, the plumbing may then be interconnected thereto. Operation and maintenance of the flooring system I O is similar to that which we described below with reference to Figures 1-2. For the flooring system 10 illustrated in Figure 13, installation of the drain pan 14 is effectuated through the IISe Of a 1()am Illsert 92 which is Set in place after which concrete substrate 88 is then poured thcrcaround. Removal of the foam insert 92 and carrying of the concrete substrate 88 results in the creation of the drain pan 14 having features similar to that described above for Figures 1-7.
Following placement of the Door grids 24 on the side walls 2O, waste products may then tall throubh the floor grids 24 and are t1115hCd dOwil lllt0 the drain outlet 18 in a manner similar to that described above.
Maintenance of the Flooring system 10 may be effectuated wherein the Moor grids 24 1171)' be removed and tray be manually hosed off or washed usily the cleaning equipment available in the facility. For example, in a commercial kitchen, it is contemplated that the floor grids 24 arc washed at each days end in a commercial dishwasher such that such floor grids 24 arc ready for reinstallation. A
commercial degreaser may be included with the flushing Iluid and which may be hand sprayed on the grates 76 prior to washing ltl order to remove grease build up. Other chelnlcals and additives may be injected in the supply line 100 to prevent grease build up on the ramp 16 and drain channel 40 areas. In thlS SflIllC lllallller, the strainer tray 74 as well as the drain basket 78 may be cleaned and checked.
It is contemplated that floor grids 24 of different colors be utilized in order to easily monitor washing c~'cles and replacement. Por e~camplc, one color o1~
the Moor grid 24 I7lay' be LISCd IUr eVell nu121be1'ed bays whllC allOther CO101' of a floor grid 24 may be utilized for odd numbered bays. Daring removal of the t7oor grids 24, the discharge ports 22 and/or spray nozzles 32 may be adjusted such that the alignment thereof is checked to ensure that such spray nozzles 32 arc spraying evenly down the 1'Ell'llps 16. Furthermore, varlOUS COlI1p011c17tS Of the plLII11b1n~T SySteln 96 S170L11C1 be checked such as the pressure tank 72, shutoff valves 102. solenoid-control-valves 1 U6 and supply lines 100.
The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that arc within the scope of the invention dt5(;105ed I7~rClIl. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each otter and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.

Claims (20)

1. A self-cleaning flooring system including at least one module, the module comprising:
a drain pan having at least one ramp and a drain outlet, the ramp sloping downwardly toward the drain outlet; and at least one side wall and one end wall forming at least a portion of a periphery of the drain pan, the end wall having at least one fluid inlet, the side wall having at least one discharge port configured to receive flushing fluid from the fluid inlet and direct flushing fluid down the ramp toward the drain outlet.

2. The self-cleaning flooring system of Claim 1 comprising a plurality of the modules, each one of the modules being configured to be connectable to one another in horizontal alignment.

3. The self-cleaning flooring system of Claim 1 wherein the side wall includes a hollow passage extending therethrough, the hollow passage being in fluid communication with the fluid inlet and being configured to deliver flushing fluid to the discharge port.

4. The self-cleaning flooring system of Claim 1 further including a removable drain basket positioned adjacent to the drain outlet and being operative to prevent solid waste from entering the drain outlet.

5. The self-cleaning flooring system of Claim 1 wherein the module further includes at least one floor grid mounted on the drain pan and being configured to support personnel standing thereupon and permitting waste products to pass therethrough.

6. The self-cleaning flooring system of Claim 1 wherein the module further includes at least one strainer tray mounted above the drain channel and being configured to prevent waste products of a predetermined size from entering the drain channel.

7. The self-cleaning flooring system of Claim 1 wherein the drain pan includes a perimeter flange extending around the drain pan periphery and being configured for supporting the drain pan.

8. The self-cleaning flooring system of Claim 1 further including at last one pressure tank in fluid communication with the fluid inlet and being configured to deliver pressurized flushing, fluid thereto.

9. A self-cleaning flooring system including at least one module, the module comprising:
a drain pan section, comprising:
a pair of ramp sections; and a channel section disposed between the ramp sections, the channel section being configured to removably interconnect the ramp sections, the channel section sloping downwardly toward a drain outlet;
wherein each one of the ramp sections is oriented to slope downwardly toward the channel section; and at least one discharge port mounted adjacent to the ramp sections and being operative to spray flushing fluid onto the ramp sections such that waste products are washed down the ramp sections toward the channel section and from the channel section toward the drain outlet.

10. The self-cleaning flooring system of Claim 9 wherein the drain outlet is located adjacent one end of the channel section, the channel section sloping downwardly toward the drain outlet.

11. The self-cleaning flooring system of Claim 9 further comprising:
at least one end plate;
wherein each module comprises a plurality of drain pan sections connected end-to-end and having an end plate mounted on at least one end thereof:

12. The self-cleaning flooring system of Claim 11 wherein the ramp sections and the channel section are formed as separate components.

13. The self-cleaning flooring system of Claim 9 comprising a plurality of the modules, each one of the modules being configured to be connectable to one another end-to-end.

14. The self-cleaning flooring system of Claim 9 wherein each one of the ramp sections includes at least one rib member disposed thereunder and being configured to support the ramp section above a substrate.

15. The self-cleaning flooring system of Claim 9 wherein the module further includes at least one floor grid mounted on the drain pan section and being configured to support personnel standing thereupon and permitting waste products to pass therethrough.

16. The self-cleaning flooring system of Claim 9 wherein the module further includes at least one strainer tray mounted above the channel section and being configured to prevent waste products of a predetermined size from entering the drain channel.

17. A self-cleaning flooring system formed in a substrate, comprising:
a drain pan having a pair of ramps sloping downwardly toward a drain channel, the drain channel sloping downwardly toward a drain outlet the drain pan defining a periphery with a perimeter flange extending therearound;
a manifold extending along a portion of the drain pan and being disposed above at least one of the ramps; and a spray nozzle fluidly connected to the manifold and being operative to spray flushing fluid down the ramp toward the drain channel and toward the drain outlet.

18. The module of Claim 17 wherein the substrate is concrete.

19. The module of Claim 17 wherein the drain pan is formed in the substrate using a removable insert configured as a male mold.

20. The module of Claim 17 wherein the insert is a foam material.