drainage device

Abstract

According to the present application there is provided a drain (10) comprising a body (14) defining a passageway (16) having opposed end regions (18) extending between and interconnecting an overflow aperture (20) defined in a container (12) and a drain aperture (22) to permit the flow of liquid therebetween, typically from the overflow aperture (20) to a drain (not shown) via the drain or plug aperture (22).

Description

Technical Field

[0001] This invention relates to a drainage device for sanitary ware. More specifically, this invention relates to a drainage device that allows overflow liquid from sanitary ware such as bathtubs or basins to be drained. Summary of the Invention

[0002] According to a first aspect of the present invention, a drainage device is provided, comprising:

[0003] The body defines a channel having opposing end regions that extend between and connect with an overflow orifice and a drain orifice defined in the container to allow liquid to flow therebetween.

[0004] It should be understood that the body may allow liquid to flow from the overflow hole through the drain hole and / or plug hole to the drain pipe.

[0005] The body may be in the form of an elongated tubular member, typically having openings defined at its opposing end regions. The shape of the body may be designed (preferably bent) to conform to a portion of the sidewalls and / or bottom of the container. The dimensions of the body may be designed to be accommodated within a portion of the sidewalls and / or bottom. In particular, the thickness of the body may be less than the thickness of the sidewalls and / or bottom of the container. The body may be substantially centrally located relative to the opposing inner and outer surfaces of the sidewalls, preferably wherein the body is substantially surrounded by the sidewalls in the molded state. Alternatively, the body may be accommodated by a receiving structure defined in the outer surface of the sidewalls. The dimensions and / or shape of the receiving structure are designed to complementaryly accommodate the body therein, such that the outer surfaces of the body and the outer surfaces of the sidewalls are flush with each other in the accommodated state. The body may have a thickness ranging from 3 mm to 20 mm, the thickness of which typically depends on the wall thickness of the container; for a container with a wall thickness of approximately 20 mm, the body preferably has a thickness of approximately 7 mm. The cross-sectional shape of the body can be any suitable geometry including parallelepipeds, polygons, circles, ovals, ellipses, squares, rectangles, and triangles, preferably generally rectangular. The body can have a width ranging from 25 mm to 150 mm, preferably about 61 mm. The walls of the body can have a thickness ranging from 0.4 mm to 2 mm, preferably about 1 mm. The body can be made of any suitable synthetic material, plastic, or metal, preferably a plastic material such as PVC (polyvinyl chloride) or ABS (acrylonitrile butadiene styrene). More preferably, the body can be made of rigid PVC.

[0006] The size of the opening of the channel leading to the body can be designed to ensure that the liquid flows through the body substantially unimpeded. Preferably, the size of the opening leading to the channel can be designed to allow the flow rate of the liquid passing through it to be similar to the flow rate of a pipe with a diameter in the range of 5 mm to 50 mm, preferably similar to the flow rate of a pipe with a diameter of about 10 mm. The opening can have a length and width in the range of 40 mm to 160 mm and 2 mm to 20 mm respectively, preferably with a length and width of about 59 mm and 4 mm respectively.

[0007] The container can be in the form of a sanitary ware container. The sanitary ware container can be in the form of any container in the group including bathtubs, sinks, and cisterns.

[0008] Reinforcing devices, preferably in the form of ribs, can be provided to strengthen the body during bending (typically during the manufacturing or production process of the body). Specifically, the ribs can be located within the body and extend along its length. More specifically, multiple ribs (preferably a pair) can be spaced apart along the width of the body to uniformly reinforce it along its width, ensuring the channel remains open during bending.

[0009] An mounting device can be provided to mount the body to the inner wall of a mold for a container. The mounting device may include a mounting member comprising an extension whose size, shape, and / or configuration can be designed to engage, preferably by an interference fit, with a receiving device (preferably in the form of a hole) defined in the inner wall of the mold. More specifically, the size, shape, and / or configuration of the extension can be designed such that, during the mounted state, the body is substantially centered relative to the opposing inner surface of the mold and / or relative to the opposing outer surface of the molded container. The length of the extension can range from 4 mm to 15 mm, preferably from 6 mm to 7 mm. The cross-section of the extension can have any suitable geometry, preferably a generally cylindrical shape and / or having a generally circular cross-section. Preferably, the mounting member may include a pair of extensions to improve the interference fit with the receiving device of the mold. The size and / or shape of the receiving hole can be designed to complementaryly receive the extensions therein, thereby allowing an interference fit engagement between them. The receiving device can be in the form of a pair of holes, typically corresponding to a pair of extensions of the mounting member.

[0010] The mounting components may include connection structures for connecting the extension to the body. Specifically, the size, shape, and / or construction of the connection structure may be designed to engage, preferably complementaryly, with the end region of the body. More specifically, the size and / or shape of the connection structure may be designed to be complementaryly accommodated by openings in the body.

[0011] A pair of mounting members can be provided for mounting the body to the inner wall of the mold through opposite end regions of the body to ensure that the body is securely mounted on the mold and to prevent displacement of the body when the molding material is pumped into the mold.

[0012] A closure member can be provided for closing openings leading to channels in opposing end regions of the body during molding of the container. The closure member can be in the form of a connection structure for mounting members. It should be understood that the closure member is used to prevent pre-molded molding material from entering the channels of the body during the pumping of pre-molded molding material into the mold of the container.

[0013] A restraining structure can be provided to prevent the extension from moving into the receiving device beyond a predetermined distance, thereby ensuring that the body is substantially centered relative to the relative inner surface of the mold and / or relative to the relative outer surface of the molded container before molding. The restraining structure can be oriented towards the bottom region of the extension, and its dimensions can be designed to inhibit its entry into the receiving device. The distance of the restraining structure from the end region of the extension can be in the range of 4 mm to 8 mm, preferably in the range of 6 mm to 7 mm.

[0014] Positioning devices can be provided for positioning opposing end regions of the body after molding the container. The positioning devices can take the form of protruding members, preferably a pair of protruding members, which can be mounted on and / or extend from opposing end regions of the body. The protruding members may have a length that allows their free end regions to protrude from the molded container, thereby indicating the position of the opposing end regions of the body to the operator. The protruding members can be integrally formed with an extension of a mounting member, which is typically an extension of the mounting member.

[0015] Positioning devices, mounting components, connecting structures, and enclosure components can be integrally formed with each other. More specifically, positioning devices, mounting components, connecting structures, and enclosure components form part of the same main body or object.

[0016] According to a second aspect of the invention, a container is provided, comprising:

[0017] bottom;

[0018] A wall that extends from the periphery of the bottom to define a containment area for holding liquid therein;

[0019] A drain hole, defined in the bottom, is provided to allow the liquid to drain from the receiving area;

[0020] An overflow orifice, defined within the wall, allows excess liquid to drain from the receiving area; and

[0021] A drainage device as described above extends between and is interconnected with the overflow hole and the drain hole to allow the liquid to flow from the overflow hole through the drain hole and / or plug hole to a drain pipe.

[0022] The container can be in the form of a sanitary ware container. The sanitary ware container can be any container in the group comprising a bathtub, sink, and water tank.

[0023] According to a third aspect of the present invention, a method for molding sanitary ware containers is provided, comprising:

[0024] The drainage device as described above is installed on the inner surface of a mold for a sanitary ware container, the drainage device being positioned relative to the mold such that the end region of the drainage device coincides with the position of an overflow hole and a drain hole that will be formed in the container once molded.

[0025] Molding material is pumped into the mold, thereby substantially surrounding the drainage device with the molding material;

[0026] Allow the molding material to harden to form the container;

[0027] Remove the mold from the molded container;

[0028] The end region of the drainage device is positioned via its protruding member, which typically protrudes from the container at the location where the overflow hole and the drain hole are to be formed;

[0029] The drain hole is formed through the bottom of the sanitary ware container, the drain hole extending through a portion of the bottom and the first end region of the drain device; and

[0030] An overflow hole is made in the sidewall of the container, passing through the second end region of the drainage device, and in doing so, a drainage channel defined by the drainage member extends between the overflow hole and the drainage hole of the container.

[0031] The process of installing the drainage device into the mold may include inserting an extension of a mounting member located in the opposite end region of the drainage device into a corresponding receiving hole defined in the mold.

[0032] The drainage hole can be roughly circular. The drainage hole can be made using a drilling machine, which typically has a hole saw-type drill bit fixed thereon.

[0033] The overflow orifice can have any suitable geometry, preferably generally elongated. It should be understood that the overflow orifice can be shaped according to the design of the container. The overflow orifice can be in the form of an elongated slot. The overflow orifice can be manufactured using a drilling machine, typically equipped with a conventional drill bit fixed thereto. Preferably, the drilling of the elongated slot can be done with the aid of a planer, also known as planing. Attached Figure Description

[0034] The drainage device, sanitary ware, and method of molding sanitary ware according to the present invention will now be described with reference to the accompanying drawings by way of the following non-limiting examples.

[0035] In the attached diagram:

[0036] Figure 1 This is a three-dimensional schematic diagram showing the drainage device according to the present invention;

[0037] Figure 2 It is a display Figure 1 A three-dimensional schematic diagram showing the disassembled drainage device;

[0038] Figure 3 This is a cross-sectional view of the drainage device;

[0039] Figure 4 This is a cross-sectional side view of the drainage device installed on the container mold;

[0040] Figure 5 This is a cross-sectional side view of the drainage device in a molded container;

[0041] Figure 6 and Figure 7 These are the displays Figure 4 and Figure 5 An enlarged cross-sectional side view of the upper part of the drainage device is shown; and

[0042] Figure 8 and 9 These are the displays Figure 4 and 5 An enlarged cross-sectional side view of the lower part of the drainage device shown. Detailed Implementation

[0043] Referring now to the accompanying drawings, reference numeral 10 generally refers to the drainage device of container 12.

[0044] The drainage device 10 includes a body 14 defining a channel 16 having opposing end regions 18 that extend between and connect with an overflow hole 20 and a drain hole 22 defined in a container 12 to allow liquid to flow therebetween, typically from the overflow hole 20 via the drain hole or plug hole 22 to a drain pipe (not shown).

[0045] The body 14 is in the form of an elongated tubular member, typically having an opening 24 defined at its opposing end regions 18. The shape of the body 14 is designed (typically bent) to conform to a portion of the sidewall 26 and / or bottom 28 of the container 12. The dimensions of the body 14 are designed to be received within a portion of the sidewall 26 and / or bottom 28. In particular, the thickness of the body 14 is less than the thickness of the sidewall 26 and bottom 28 of the container 12. The opposing inner surface 30 and outer surface 32 of the body 14 relative to the sidewall 26 are substantially centrally located, wherein the body 14 is substantially surrounded by the sidewall 26 in the molded state. Alternatively, although not shown, the body 14 may be received by a receiving structure (not shown) defined in the outer surface 32 of the sidewall 26. The dimensions and shape of the receiving structure (not shown) are designed to complementaryly receive the body 14 therein, such that the outer surface of the body 14 and the outer surface of the sidewall 26 are flush with each other in the received state. It should be understood that the thickness and arrangement of the body 14 relative to the sidewalls 26 and bottom 28 of the container 12 minimize the loss of structural integrity of the container 12. The body 14 may have a thickness ranging from 3 mm to 20 mm, and the thickness of the body typically depends on the wall thickness of the container 12; for a container with approximately 20 mm thick walls, the body 14 has a thickness of approximately 7 mm. The cross-sectional shape of the body 14 is any suitable geometry including parallelepipeds, polygons, circles, ovals, ellipses, squares, rectangles, and triangles, and is typically approximately rectangular, such as... Figure 3 As shown most clearly in the diagram. The body 14 may have a width ranging from 45 mm to 90 mm, typically about 61 mm. The wall 34 of the body 14 may have a thickness ranging from 0.4 mm to 2 mm, typically about 1 mm. The body 14 is made of any suitable synthetic material, plastic or metal, typically rigid PVC (polyvinyl chloride).

[0046] The opening 24 of the channel 16 leading to the body 14 is sized to ensure that liquid flows through the body 14 substantially unimpeded. Typically, the opening 24 is sized to allow a flow rate similar to that of a pipe with a diameter ranging from 5 mm to 50 mm, and generally similar to that of a pipe with a diameter of approximately 10 mm. The opening 24 has a length and width ranging from 40 mm to 160 mm and from 2 mm to 20 mm, respectively, and generally has a length and width of approximately 59 mm and 4 mm, respectively. It should be understood that while specific dimensions are provided, the dimensions of the opening 24 depend on the dimensions of the container 12 to be molded.

[0047] Container 12 is in the form of a sanitary ware container. The sanitary ware container can be any of the groups including bathtubs, sinks, and water tanks.

[0048] A reinforcing device in the form of ribs 36 is provided for reinforcing the body 14 during bending (typically during the manufacture or production of the body 14). Specifically, the ribs 36 are located within the body 14 and extend along its length. More specifically, a plurality of ribs 36 (typically a pair) are spaced apart along the width of the body 14 to uniformly reinforce the body 14 along its width, ensuring that the channel 16 remains open during bending of the body 14.

[0049] A mounting device 38 is provided for mounting the body 14 to the inner wall 40 of a mold 42 for a container 12. The mounting device 38 includes a mounting member 44 comprising a pair of extensions 46, the extensions 46 being sized, shaped, and configured to engage, typically by an interference fit, with a receiving device defined in the inner wall 40 of the mold 42 in the form of an aperture 48. More specifically, the extensions 46 are sized, shaped, and configured such that, during the mounted state, the body 14 is substantially centered relative to the opposing inner surface 50 of the mold 42 or relative to the opposing outer surface 32 of the molded container 12. It should be understood that the substantially centered body 14, by forming a cavity or channel 16 therein, serves to minimize the loss of structural integrity of the container 12 to be molded. The length of the extensions 46 is in the range of 4 mm to 15 mm, typically in the range of 6 mm to 7 mm, depending on the degree of shrinkage during manufacturing. The cross-section of extension 46 has any suitable geometry, typically a generally cylindrical shape with a generally circular cross-section. The size and shape of receiving hole 48 are designed to complementarily receive extension 46 therein, thereby allowing an interference fit between them.

[0050] Mounting member 44 includes a connection structure 52 for connecting extension 46 to body 14. Specifically, the dimensions, shape, and construction of connection structure 52 are designed to generally complementarily engage end regions 18 of body 14. More specifically, the dimensions and shape of connection structure 52 are designed to be complementarily accommodated by openings 24 in body 14.

[0051] A pair of mounting members are provided for mounting the body 14 to the inner wall 40 of the mold 42 via opposite end regions 18 of the body 14, to ensure that the body 14 is securely mounted on the mold 42, and to prevent displacement of the body 14 when molding material is pumped into the mold 42.

[0052] A closure member (typically in the form of a connection structure 42 of mounting device 38) is provided for closing the opening 24 leading to the channel 16 in the opposite end regions 18 of the body 14 during molding of the container 12. It should be understood that the closure member is used to prevent pre-molded molding material from entering the channel 16 of the body 14 during the pumping of pre-molded molding material into the mold 42 of the container 12.

[0053] A restraining structure 54 is provided to prevent the extension 46 from moving into the receiving hole 48 beyond a predetermined distance, thereby ensuring that the body 14 is substantially centered relative to the inner surface 50 of the mold 42 and the outer surface 32 of the molded container 12 before molding the container 12. The restraining structure 54 faces the bottom region of the extension 46 and is sized to prevent it from entering the receiving hole 48. In use, the operator presses the extension 46 into the receiving hole 48 until the restraining structure 54 abuts the edge of the hole 48, thus preventing the extension 46 from moving further into the receiving hole 48. At this point, the operator will realize that the body 14 is correctly positioned relative to the mold 42. The distance of the restraining structure 54 from the end region of the extension 46 is in the range of 4 mm to 8 mm, typically in the range of 6 mm to 7 mm.

[0054] It should be understood that once container 12 has been molded, overflow hole 20 and drain hole 22 need to be manufactured, which are typically made by drilling holes in container 12 at predetermined locations. Overflow hole 20 is typically located at the maximum desired liquid height in the inner surface 30 of container 12; while drain hole 22 is typically located in the bottom 28 of container 12, usually its lowest part, to ensure that as much liquid as possible is drained during use.

[0055] A positioning device in the form of a protruding member 56 is provided for positioning the opposing end regions 18 of the body 14 after molding the container 12. It should be understood that the positioning device allows an operator to drill an overflow hole 20 and a drain hole 22 at a location coinciding with the end region 18 of the body 14, thereby opening a channel 16 and defining an overflow channel 58 in the wall 26 and bottom 28 of the container 12, the channel 58 extending from the overflow hole 20 to the drain hole 22. The protruding member 56 is mounted on or extends from the opposing end region 18 of the body 14. The protruding member 56 has a length that allows its free end region to protrude from the molded container 12, thereby indicating to the operator the position of the opposing end regions of the body 14. The protruding member 56 is integrally formed with an extension 46 of a mounting member 44, which is typically an extension 46 of the mounting member 44.

[0056] As shown in the attached figure, the protruding member 56, the mounting member 44, and the connecting structure 52 are integrally formed together.

[0057] According to a second aspect of the invention, a container 12 is provided, comprising a bottom 28, a wall 26 extending from the periphery of the bottom 28 to define a receiving area (not shown) for containing liquid therein, a drain hole 22 defined in the bottom 28 for allowing liquid to drain from the receiving area (not shown), an overflow hole 20 defined in the wall 26 for allowing excess liquid to drain from the receiving area (not shown), and a drainage device 10 as described above, the drainage device 10 extending between and interconnecting the overflow hole 20 and the drain hole 22 to allow liquid to flow from the overflow hole 20 through the drain hole or plug hole 22 to a drain pipe (not shown).

[0058] Container 12 is in the form of a sanitary ware container. The sanitary ware container can be any of the groups including bathtubs, sinks, and water tanks.

[0059] According to a third aspect of the invention, a method for molding a sanitary ware container 12 is provided, comprising: mounting a drain device 10 as described above to an inner surface 50 of a mold 42 for the sanitary ware container 12, the drain device 10 being positioned relative to the mold 42 such that an end region 18 of the drain device 10 coincides with the location of an overflow hole 20 and a drain hole 22 that will be formed in the container 12 once molding; pumping molding material (not shown) into the mold 42, thereby substantially surrounding the drain device 10 with the molding material; allowing the molding material to harden to form the container 12; and removing the mold 42 from the molded container 12. In addition, the end region 18 of the drain device 10 is positioned via its protruding member 56, which typically protrudes from the container 12 at the location where the overflow hole 20 and the drain hole 22 are to be formed; a drain hole 22 is formed through the bottom 28 of the container 12, extending through the bottom 28 and a portion of the first end region 18 of the drain device 10, and an overflow hole 20 is formed in the side wall 26 of the container and through the second end region 18 of the drain device 10, and in doing so, a drain channel 56 defined by the drain member 10 is opened, which extends between the overflow hole 20 and the drain hole 22 of the container 12.

[0060] The process of installing the drainage device 10 into the mold includes inserting an extension 46 of the mounting member 44 located in the opposite end region 18 of the drainage device 10 into a corresponding receiving hole 48 defined in the mold 42.

[0061] The drain hole 22 is generally circular. The drain hole 22 is manufactured using a drilling machine, which typically has a hole saw-type drill bit fixed thereon.

[0062] The overflow orifice 20 has any suitable geometry, but is generally elongated. The overflow orifice 20 is in the form of an elongated slot. The overflow orifice 20 is manufactured using a drilling machine, typically equipped with a conventional drill bit fixed thereto. Typically, the drilling of the elongated slot is done with the aid of a planer.

[0063] Of course, it should be understood that the drainage device according to the invention is not limited to the precise structural and functional details described above with reference to the accompanying drawings, and can be varied as needed.

[0064] Although only certain embodiments of the invention have been described herein, any person skilled in the art will understand that other modifications, variations, and possibilities of the invention are possible. Such modifications, variations, and possibilities are therefore considered to fall within the spirit and scope of the invention and thus form part of the invention as described and / or exemplified herein. It should also be understood that the embodiments are provided to further illustrate the invention and to assist those skilled in the art in understanding it, and should not be construed as unduly limiting the reasonable scope of the invention.

[0065] The inventors believe that the advantages of the drainage device according to the invention are: it allows drainage channels to be formed within the wall of the sanitary ware, thereby removing unsightly pipes extending from the overflow hole to the bottom of the sanitary ware from the outside. Furthermore, due to the material of the drainage device and the way it is mounted on the mold, pumping mold material into the mold does not damage the structure or location of the drainage device, thus minimizing the loss of structural integrity of the molded sanitary ware. Moreover, using the drainage device according to the invention during the molding of the sanitary ware reduces the possibility of malfunctions due to changes in the wall thickness of the sanitary ware after molding. The inventors believe another advantage is that the space between the bottom of the bathtub and the floor can be reduced, thus reducing the height of the bathtub for easier entry and exit.

Claims

1. A drainage device comprising: The body defines a channel having opposing end regions, the channel extending between and connecting to an overflow orifice and a drain orifice defined in the container to allow liquid to flow therebetween; A reinforcing device for reinforcing the body during bending; An installation device for mounting the main body to the inner wall of a mold for the container; The mounting device includes a mounting member, the mounting member including an extension whose size, shape and construction are designed to engage with a receiving device defined in the inner wall of the mold; A positioning device for positioning opposite end regions of the body after molding the container; the positioning device is in the form of a protruding member mounted on and protruding from the opposite end regions of the body to a length such that the protruding member protrudes from the container after the body is mounted in the mold and the container is molded in the mold.

2. The drainage device according to claim 1, characterized in that: The main body is in the form of a slender tubular component.

3. The drainage device according to claim 1, characterized in that: The shape of the main body is designed to conform to the sidewalls of the container.

4. The drainage device according to claim 1, characterized in that: The shape of the main body is designed to conform to a portion of the sidewalls and bottom of the container.

5. The drainage device according to claim 4, characterized in that: The dimensions of the main body are designed to be accommodated within the sidewalls.

6. The drainage device according to claim 4, characterized in that: The dimensions of the main body are designed to be accommodated within a portion of the sidewalls and the bottom.

7. The drainage device according to any one of claims 4-6, characterized in that: The thickness of the main body is less than the thickness of the sidewall of the container.

8. The drainage device according to any one of claims 4-6, characterized in that: The thickness of the main body is less than the thickness of the side walls and bottom of the container.

9. The drainage device according to any one of claims 4-6, characterized in that: The inner and outer surfaces of the main body relative to the sidewall are substantially centered.

10. The drainage device according to claim 1, characterized in that: The container is in the form of a sanitary ware container.

11. The drainage device according to claim 10, characterized in that: The sanitary ware container is in the form of any container in the group including bathtubs, sinks and water tanks.

12. The drainage device according to claim 1, characterized in that: The reinforcing device is in the form of a rib structure, which is located within the main body and extends along the length of the main body.

13. The drainage device according to claim 1, characterized in that: The dimensions, shape, and construction of the extension are designed to engage with the receiving device, which is defined as a hole in the inner wall of the mold, by an interference fit.

14. The drainage device according to claim 1, characterized in that: The dimensions, shape, and construction of the extension are designed such that, during the installation state, the body is substantially centered relative to the inner surface of the mold.

15. The drainage device according to claim 13 or 14, characterized in that: The extension has a length ranging from 4 mm to 15 mm.

16. The drainage device according to claim 1, characterized in that: The mounting component includes a connection structure for connecting the extension to the body.

17. The drainage device according to claim 1, characterized in that: A pair of mounting members are provided for mounting the body to the inner wall of the mold through opposite end regions of the body, to ensure that the body is securely mounted on the mold, and to prevent the body from shifting when molding material is pumped into the mold.

18. The drainage device according to claim 1, characterized in that: A closing member is provided for closing the openings leading to the channel in opposite end regions of the body during the molding of the container.

19. The drainage device according to claim 1, characterized in that: An inhibiting structure is provided to prevent the extension from moving into the receiving device beyond a predetermined distance, thereby ensuring that the body is substantially centered relative to the inner surface of the mold or relative to the outer surface of the molded container before the container is molded.

20. The drainage device according to claim 1, characterized in that: The protruding member has a length that allows its free end region to protrude from the molded container, thereby indicating to the worker the position of the opposite end regions of the body.

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