AU2023208108A1 - Drain apparatus - Google Patents

Abstract

A method of connecting a drain aperture of a sanitary appliance and a waste fluid conduit using a drain apparatus, the drain apparatus comprising: a drain pan having a first end with an opening to receive fluid from the drain aperture and a second end with an outlet for connection with the waste fluid conduit, wherein the first end and second end are in fluid communication to allow fluid to drain from the drain aperture to the waste fluid conduit; and a cover at least partially enclosing the drain pan, wherein the cover has a face with an area greater than a cross-sectional area of the drain aperture, wherein the cover is adjustable on the drain pan, such that, in use, a distance between the face of the cover and the first end of the drain pan can be adjusted; the method comprising: positioning the drain apparatus above the waste fluid conduit; connecting the outlet of the drain pan to the waste fluid conduit; fitting or adjusting the cover relative to the drain pan such that the face of the cover is level with a surrounding floor; if required, trimming the first end of the drain pan so that the first end is level with the surrounding floor; installing the sanitary appliance such that the drain aperture is above the drain apparatus; forming a hole in the cover at a location vertically aligned with the drain aperture of the sanitary appliance such that fluid can flow from the sanitary appliance to the waste fluid conduit via the drain apparatus. 2/6 10 46148 40 44 o ~38 32 22 34 24 26 30 20 36 28 FIG. 2

Description

2/6 10 46148 40

44

o ~38

32

22

34 24 26 30 20 36 28

FIG. 2

Drain Apparatus

TECHNICAL FIELD The invention relates to a drain apparatus for a sanitary appliance and a method of connecting a sanitary appliance to a waste conduit using the drain apparatus.

BACKGROUND When installing a sanitary appliance (e.g. a shower, bath tub, toilet, sink) in a building, it is necessary to connect the outlet of the appliance to a waste conduit of the building. Often the waste conduit will be in a sub-floor of the building and rise up to meet the sanitary appliance. Providing a secure and water-tight connection between the waste conduit and the sanitary appliance is essential to allow for the proper functioning of the sanitary appliance as well as ensuring there is no unintended damage to the building from leaks.

Conventionally, this secure connection may be made by creating a hole in the sub-floor, inserting a drain pan and filling the surrounding floor with concrete. A plumber then installs the sanitary appliance over the drain pan, connecting the outlet of the appliance to a drainage aperture in the drain pan. The top of the drain pan must be level with the surrounding concrete, otherwise the sanitary appliance cannot be properly installed. In cases where the concrete has not been laid correctly and the top of the drain pan is above the level of the concrete, the concrete around the drain pan must be removed and the drain pan reinstalled. This can create substantial inefficiencies in the installation process.

In this context, there is a need for an improved drain apparatus for sanitary appliances.

SUMMARY According to a first aspect of the present invention, there is provided a method of connecting a drain aperture of a sanitary appliance and a waste fluid conduit using a drain apparatus, the drain apparatus comprising: a drain pan having a first end with an opening to receive fluid from the drain aperture and a second end with an outlet for connection with the waste fluid conduit, wherein the first end and second end are in fluid communication to allow fluid to drain from the drain aperture to the waste fluid conduit; and a cover at least partially enclosing the drain pan, wherein the cover has a face with an area greater than a cross sectional area of the drain aperture, wherein the cover is adjustable on the drain pan, such that, in use, a distance between the face of the cover and the first end of the drain pan can be adjusted; the method comprising: positioning the drain apparatus above the waste fluid conduit; connecting the outlet of the drain pan to the waste fluid conduit; fitting or adjusting the cover relative to the drain pan such that the face of the cover is level with a surrounding floor; if required, trimming the first end of the drain pan so that the first end is level with the surrounding floor; installing the sanitary appliance such that the drain aperture is above the drain apparatus; forming a hole in the cover at a location vertically aligned with the drain aperture of the sanitary appliance such that fluid can flow from the sanitary appliance to the waste fluid conduit via the drain apparatus.

In some embodiments, the method further comprises filling the area around the drain pan with flowable material and thereafter fitting or adjusting the cover.

In some embodiments, adjusting the cover relative to the drain pan involves rotating the cover relative to the drain pan via threads formed on each.

In some embodiments, the cover is rotated by fitting a tool to recesses formed in the face of the cover and applying a torque to the cover.

In some embodiments, the method further comprises locking the cover in place with an adhesive.

In some embodiments, the cover forms a floor for the sanitary appliance in conjunction with the surrounding material.

In some embodiments, the hole is formed in the cover after installing a base of the sanitary appliance.

In some embodiments, the base is the base of a shower, toilet, bath tub or sink.

According to a second aspect of the present invention, there is provided a drain apparatus comprising: a drain pan having a first end with an opening to receive fluid from a drain aperture and a second end with an outlet for connection with a waste fluid conduit, wherein the first end and second end are in fluid communication to allow fluid to drain from the drain aperture to the waste fluid conduit; and a cover to at least partially enclose the first end of the drain pan, wherein the cover has a face with an area greater than a cross-sectional area of the drain aperture, said face configured to have a hole formed therein after the drain pan has been connected to the waste fluid conduit such that the hole and drain aperture are in vertical alignment, wherein the cover is adjustable on the drain pan, such that, in use, a distance between the face of the cover and the first end of the drain pan can be adjusted.

In some embodiments, the cover is releasably engageable with the drain pan.

In some embodiments, the area of the face of the cover is at least two times larger than the cross-sectional area of the drain aperture.

In some embodiments, the drain pan comprises a cylindrical body between the first and the second end.

In some embodiments, the cover is cylindrical and comprises threads about its periphery, which engage with threads in the drain pan, whereby the cover is adjustable on the drain pan.

In some embodiments, the face of the cover comprises at least two formations to facilitate rotation of the cover via a tool adapted to cooperate with the formations.

In some embodiments, the formations are recesses.

In some embodiments, the cover has a diameter of approximately 300mm.

In some embodiments, the distance between the face of the cover and the first end of the drain pan can be adjusted by at least 40mm.

In some embodiments, the face comprises reinforcing ribs.

In some embodiments, the ribs form a lattice structure.

In some embodiments, the drain pan has a lip extending from an upper edge.

In some embodiments, the drain apparatus is manufactured of a plastics material.

BRIEF DESCRIPTION OF THE FIGURES Embodiments of the present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings briefly described as follows.

Figure 1 is an elevation view of a drain apparatus installed in a floor. Figure 2 is an upper perspective view of the drain apparatus shown in Figure 1. Figure 3 is an exploded elevation view of the drain apparatus shown in Figure 1. Figure 4 is an upper perspective view of the cover of the drain apparatus shown in Figure 1. Figure 5 is a lower perspective view of the cover of the drain apparatus shown in Figure 1. Figure 6 is a top view of the cover of the drain apparatus shown in Figure 1. Figure 7 is a bottom view of the cover of the drain apparatus shown in Figure 1. Figure 8 is a section view of the cover of the drain apparatus shown in Figure 6 along the line A-A.

DETAILED DESCRIPTION In order to install a sanitary appliance, such as a shower, bath tub, toilet or sink, it is necessary to connect the drain of the appliance to a waste fluid conduit. Schematically illustrated in Figure 1 is an example installation showing a base (2) of a sanitary appliance having a drain aperture (4) that is connected to a waste fluid conduit (6) by means of a drain apparatus (10) according to one example of the present invention. The drain apparatus (10) and waste fluid conduit (6) are embedded within the subfloor (8) of a building (not shown). The subfloor (8) is a structure that supports the base (2) of the sanitary appliance and will form part of the floor of a room in which the sanitary appliance is situated. The subfloor (8) is typically formed after the waste conduit (6) has been fitted within the building and is usually prepared by filling the area surrounding the waste conduit (6) with a flowable material, such as concrete, and then allowing the material to set.

As can be seen in Figure 1, the drain aperture (4) is vertically misaligned with the waste fluid conduit (6). Nevertheless, the drain aperture (4) must be connected to the waste fluid conduit (6) in a leak tight manner to ensure the proper functioning of the sanitary appliance. Therefore, in the arrangement shown in Figure 1, drain apparatus (10) is used to connect the drain aperture (4) and the waste fluid conduit (6).

Drain Apparatus The drain apparatus (10) comprises a drain pan (20) and a cover (40).

The drain pan (20) has a first end (22) with an opening (24) for receiving fluid from the drain aperture (4) and a second end (26) with an outlet (28) for connection with the waste fluid conduit (6). The first end (22) and second end (26) are in fluid communication to allow fluid to drain from the drain aperture (4) of the sanitary appliance to the waste fluid conduit (6) when in use. A body (30) connects the first and second ends (22, 26). In the illustrated example, the body (30) is substantially cylindrical. A helical screw-thread (32) is formed on an internal surface of the wall (36) of the body (30), which is engageable with a corresponding screw-thread formation (44) on the cover (40) to enable reversible attachment of the cover (40) to the drain pan (20). The wall thickness of the drain pan (20) is approximately 3mm.

The drain pan (20) has substantially straight side walls (36) and an angled base (38). The walls (36) extend substantially vertically when installed. It has been found that this configuration reduces the risk of solid waste such as paper getting stuck to the walls of the drain pan (20). However, in other embodiments, the body (30) of the drain pan (20) may reduce in diameter towards the second end (26) to form a bowl or funnel shape. The drain pan (20) illustrated is a unitary component, but the drain pan (20) may also be formed from multiple pieces.

The drain pan (20) has a lip (34) extending from an edge of the first end (22). Specifically, the lip (34) extends radially outward from the top edge of the wall (36) to form a flange. Screws or other suitable fasteners may be driven through the flange to secure the flange to the subfloor or other substrate below the lip (34).

The drain cover (40) at least partially encloses the drain pan (20). In the illustrated embodiment, the cover (40) totally encloses the drain pan (20). The cover (40) is configured to have a hole (46) formed therein after the drain pan (20) has been connected to the waste fluid conduit (6). This allows the hole (46) to be formed in a location such that the hole (46) and drain aperture (4) are in substantially vertical alignment when the base (2) of the sanitary appliance is installed.

The drain apparatus (10), including the cover (40), is manufactured of a plastics material, which allows for easy removal of material from the cover (40) when forming the hole (46). However, the cover (40) may be formed from any suitable plumbing material.

The cover (40) has a face (42), which has an area greater than the cross-sectional area of a typical drain aperture (4). As shown in Figure 1, the cover (40) has a cross-sectional area at least two times larger than the cross-sectional area of the drain aperture (4). Specifically, the cover (40) has a diameter of approximately 300mm, preferably 295 mm, to fit the opening of the drain pan (20). Since a hole can be formed anywhere within the cross-section of the face (42) that is not coincident with the edge of the cover (40), the drain apparatus (10) is able to accommodate misalignment between the drain aperture (4) and the waste fluid conduit (6).

Additionally, the cover (40) is adjustable on the drain pan (20), such that, in use, a distance between the face (42) of the cover (40) and the first end (22) of the drain pan (20) can be adjusted. Advantageously, this allows the cover (40) to be adjusted to suit the height of a surrounding floor, such as the subfloor (8) shown in Figure 1. In effect, the cover (40) when adjusted to the correct height forms part of a floor of the room in conjunction with the surrounding material.

As shown in Figures 6 and 7, the cover (40) has a circular face (42) and is broadly formed as a cylinder. The cover (40) further comprises threads (44) about its periphery, which engage with threads (32) formed on the inside of the drain pan (20), whereby the cover (40) is releasably engageable with and also adjustable on the drain pan (20). In alternative embodiments, the threads (44) of the cover (40) may be formed on an inner face of sidewalls of the cover (40) and threads (32) of the drain pan (20) may be formed on an external face of the drain pan body (30).

The cover (40) can, thus, be adjusted relative to the drain pan (20) by rotating the cover (40) relative to the drain pan (20) on the threads (32, 44) formed on each. The degree to which the cover (40) can be adjusted relative to the drain pan (20) depends on the height (A) of the cover (40). The cover (40) may be adjustable so that the distance between the face (42) of the cover (40) and the first end (22) of the drain pan (20) may be set between 0 and100mm, and preferably up to at least 40mm above or below the first end (22). The height (A) of the cover (40) must be less than the height (B) of the straight side walls (36) of the drain pan (20), so that the cover (40) can sit flush on the drain pan (20), if necessary. In the illustrated embodiment, the height (A) of the cover (40) is approximately 50mm and the height (B) of the straight side walls (36) is 90mm.

The face (42) of the cover (40) comprises at least two formations (48) to facilitate rotation of the cover (40) via a tool (not shown) adapted to cooperate with the formations (48). As shown in Figure 2, the cover (40) comprises four formations (48) provided as recesses, but in alternative embodiments there may also be two, three or five. In the illustrated embodiment, the formations (48) are cylindrical bores having a diameter of approximately 3mm and a depth of 10mm.

The face (42) of the cover (40) comprises reinforcing structures, such as reinforcing ribs (50). As shown in Figure 5, the ribs (50) form a lattice structure and extend from the face (42) toward the drain pan (20) when the cover (40) is fitted to the drain pan (20). The ribs (50) in the illustrated embodiment are 3mm in thickness and 10mm in depth, but may be any suitable dimension.

Method of Using Drain Apparatus To connect the drain aperture (4) of a sanitary appliance and a waste fluid conduit (6) using the drain apparatus (10), the drain apparatus (10) is positioned above the waste fluid conduit (6). The outlet (28) of the drain pan (20) is then connected to the waste fluid conduit (6). The cover (40) should then be fitted or, if already fitted, adjusted relative to the drain pan (20) such that the face (42) of the cover (40) is level with the subfloor (8), which may be formed before or after the cover (40) is installed. The cover (40) is adjusted relative to the drain pan (20) by rotating the cover (40) relative to the drain pan (20) on threads (32, 44) formed on each. Specifically, the cover (40) is rotated by fitting a tool to recesses (48) formed in the face (42) of the cover (40) and applying a torque to the cover (40). If required, the first end (22) of the drain pan (20) may be trimmed so that the first end (22) is level with the subfloor (8).

If the cover (40) is fitted before the subfloor (8) is formed, the cover (40) may be fitted to the drain pan (20) with a protective sticker adhered over the apparatus (10) to prevent the flowable material or any other debris fouling the threads (32, 44) or entering the drain pan (20) while the flowable material is being poured. Alternatively, the cover (40) may be fitted after the area around the drain pan (20) is filled with flowable material. Again a suitable temporary barrier may be used to prevent the drain pan (20) and associated components from becoming fouled by the flowable material.

Once the cover is adjusted so that the face (42) is level with the surrounding floor, the cover (40) is then locked in place with an adhesive. Specifically, the adhesive may be applied to an interface between the cover (40) and the drain pan (20). Any suitable adhesive known in the art may be used. Preferably, a plumbing adhesive or silicone, such as Admil N600 is used.

The sanitary appliance may then be installed such that the drain aperture (4) is above the drain apparatus (10). Once the base (2) of the sanitary appliance is in place and the drain aperture (4) in position, a hole may be cut in the cover (40) at a location (46) vertically aligned with the drain aperture (4) such that fluid can flow from the sanitary appliance to the waste fluid conduit (6) via the drain apparatus (10).

While various features of embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Further, although methods have been described as a sequence of steps, it should be apparent that the steps of such methods may be performed in any order and may include fewer or more steps. The relevant steps may also be performed sequentially or simultaneously as appropriate.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims (21)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A method of connecting a drain aperture of a sanitary appliance and a waste fluid conduit using a drain apparatus, the drain apparatus comprising: a drain pan having a first end with an opening to receive fluid from the drain aperture and a second end with an outlet for connection with the waste fluid conduit, wherein the first end and second end are in fluid communication to allow fluid to drain from the drain aperture to the waste fluid conduit; and a cover at least partially enclosing the drain pan, wherein the cover has a face with an area greater than a cross-sectional area of the drain aperture, wherein the cover is adjustable on the drain pan, such that, in use, a distance between the face of the cover and the first end of the drain pan can be adjusted; the method comprising: positioning the drain apparatus above the waste fluid conduit; connecting the outlet of the drain pan to the waste fluid conduit; fitting or adjusting the cover relative to the drain pan such that the face of the cover is level with a surrounding floor; if required, trimming the first end of the drain pan so that the first end is level with the surrounding floor; installing the sanitary appliance such that the drain aperture is above the drain apparatus; forming a hole in the cover at a location vertically aligned with the drain aperture of the sanitary appliance such that fluid can flow from the sanitary appliance to the waste fluid conduit via the drain apparatus.

2. The method according to claim 1, wherein the method further comprises filling the area around the drain pan with flowable material and thereafter fitting or adjusting the cover.

3. The method according to any one of the preceding claims, wherein adjusting the cover relative to the drain pan involves rotating the cover relative to the drain pan via threads formed on each.

4. The method according to claim 3, wherein the cover is rotated by fitting a tool to recesses formed in the face of the cover and applying a torque to the cover.

5. The method according to any of the preceding claims further comprising locking the cover in place with an adhesive.

6. The method according to any one of the preceding claims, wherein the cover forms a floor for the sanitary appliance in conjunction with the surrounding material.

7. The method according to any one of the preceding claims, wherein the hole is formed in the cover after installing a base of the sanitary appliance.

8. The method according to claim 7, wherein the base is the base of a shower, toilet, bath tub or sink.

9. A drain apparatus comprising: a drain pan having a first end with an opening to receive fluid from a drain aperture and a second end with an outlet for connection with a waste fluid conduit, wherein the first end and second end are in fluid communication to allow fluid to drain from the drain aperture to the waste fluid conduit; and a cover to at least partially enclose the first end of the drain pan, wherein the cover has a face with a an area greater than a cross-sectional area of the drain aperture, said face configured to have a hole formed therein after the drain pan has been connected to the waste fluid conduit such that the hole and drain aperture are in vertical alignment, wherein the cover is adjustable on the drain pan, such that, in use, a distance between the face of the cover and the first end of the drain pan can be adjusted.

10. The drain apparatus according to claim 9, wherein the cover is releasably engageable with the drain pan.

11. The drain apparatus according to any one of claims 9 or 10, wherein the area of the face of the cover is at least two times larger than the cross-sectional area of the drain aperture.

12. The drain apparatus according to any one of claims 9 to 11, wherein the drain pan comprises a cylindrical body between the first and the second end.

13. The drain apparatus according to claim 12, wherein the cover is cylindrical and comprises threads about its periphery, which engage with threads in the drain pan, whereby the cover is adjustable on the drain pan.

14. The drain apparatus according to claim 13, wherein the face of the cover comprises at least two formations to facilitate rotation of the cover via a tool adapted to cooperate with the formations.

15. The drain apparatus according to claim 14, wherein the formations are recesses.

16. The drain apparatus according to any one of claims claim 13 to 15, wherein the cover has a diameter of approximately 300mm.

17. The drain apparatus according to any one of claims 9 to 16, wherein the distance between the face of the cover and the first end of the drain pan can be adjusted by at least mm.

18. The drain apparatus according to any one of claims 9 to 17, wherein the face comprises reinforcing ribs.

19. The drain apparatus according to claim 18, wherein the ribs form a lattice structure.

20. The drain apparatus according to any one of claims 9 to 19, wherein the drain pan has a lip extending from an upper edge.

21. The drain apparatus according to any one of claims 9 to 20, wherein the drain apparatus is manufactured of a plastics material.