Note: Descriptions are shown in the official language in which they were submitted.
2171383
PH-1849
ENCAPSULATEI) OVERFLOW SYSTEM FOR TUBS AND THE LIRE
BACKGROUND OF THE INVENTION
The present invention is directed to an overflow
system for sanitary fixtures such as bathtubs, spas, whirlpool
tubs and the like, and in particular to an overflow system
which interconnect: the overflow opening and the drain opening
of a sanitary fixture, especially designed to be attached to
the fixture during manufacture or before shipping.
Sanitary :Fixtures such as bathtubs, spas, whirlpool
tubs and the like are generally provided with a drain opening
located in the floor of the fixture and an overflow opening
located in the end wall nearest the overflow opening and
positioned proximaite the top rim of the fixture. A conduit or
tube is generally provided to interconnect the drain opening
and the overflow opening such that when water reaches the level
of the overflow opESning, the water will flow therethrough, into
the conduit and ini~o the drain coupled to the drain opening.
This prevents water from flowing over the top of the rim or
edge of the f fixture .
The overflow ;system is generally formed as an integral
passage in chinaware and cast iron fixtures. Alternatively, in
enameled steel and acrylic fixtures, the overflow system is
independent from the fixture and is installed on the fixture at
installation. Thi:~ procedure is time consuming and
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inconvenient, increasing the labor costs involved in installing
a tub.
Commonly assigned U.S. Patent No. 5,179,740 is
directed to an encapsulated multicomponent overflow system for
sinks. The overflow system includes a tube formed from a
thermoplastic material, bent to conform to the curvature of the
sink, which interconnects the overflow opening to the drain.
The system further includes a pair of coupling means to couple
the first end of the tube to the overflow opening and to couple
the second end of t:he tube to the drain. Consequently, in
order to securely affix the system to the sink, the overflow
system must be encapsulated with plastic material which is
applied to the none:xposed bottom surface of the sink during
manufacture limiting the type of material from which the sink
can be manufactured. Additionally, an internal support in the
tube is required to maintain rigidity of the tube during the
application of the plastic layer. Furthermore, this technique
is limited to sinker. Sinks typically have a remote drain
stopper assembly independent from the overflow system, while
tubs typically integrate the remote drain stopper assembly into
the overflow system. The encapsulated overflow system of U.S.
Patent No. 5,179,74.0 does not include a remote drain stopper
assembly and is not: applicable to tubs. Moreover, the overflow
system of U.S. Pats:nt No. 5,179,740 includes a plurality of
components each of which requires a separate mold and thus
separate manufacture which add to the expense and time involved
in the manufacture of the overflow system. No attempts have
been made to incorporate a one-piece overflow system in a tub
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at the time of manufacture to reduce the time and labor
involved in instal7.ing tubs and the like. No attempts have
been made to incorporate an overflow system in a tub which
system may or may not be encapsulated.
Thus, it is apparent that a new type of overflow
system for tubs is desirable in order to reduce the time and
labor involved in installing tubs. It is desirable in
providing an overflow system for a sanitary fixture that the
components be capable of attachment to the fixture during
manufacture or prior to shipment. It is preferable that the
overflow system comprises one component and that it be able to
withstand the press>ures exerted during the molding process. It
is important in providing an overflow system for a sanitary
fixture that the components be capable of attachment to the
fixture with or without the addition of an encapsulation layer.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to reduce
the time necessary for installation of a sanitary fixture.
It is another object of the invention to ease the
installation of a sanitary fixture.
It is a related object of the invention to optionally
encapsulate the overflow system on the sanitary fixture.
It is a further object of the invention to
manufacture an overflow system that is easy and inexpensive to
manufacture.
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These and other objects aid advantages are
achieved by the present invention which provides an
integral overflow system for a sani~ary fixture such as
a tub which directs water from the overflow opening to
the drain. The sanitary fixture inc=ludes a rigid shell
having a finish side and a non-finish side. A tube or
conduit interconnects the overflow opening to the
drain.
In a preferred embodiment, the overflow
system is a one-piece conduit i_n thE: shape of a trough
having a perip:~eral. flange formed to fit the curvature
of each particular t.ub. The first end o:>= the conduit
is configured to cover the overflow opening of the
shell and the second end is configured to discharge
water in the conduit into the drain. The conduit may
be welded or o1_herwise adhered to the shell. Moreover,
it is subsequently encapsulated with a layer of
polymeric material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully appreciated
from the following detailed description when the same
is considered _~n connection with the accompanying
drawings in wh=_ch
Fig. 1 is an exploded perspective view of the
components of a prior art overflow system which must be
attached during installation of a tub;
Fig. 2 is a perspective view of a sanitary
fixture in the form of a tub which incorporates the
one-piece component integral overflow system
constructed in accordance with the present invention;
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Fig. 3 i.s a front elevational view of the tub of Fig.
2;
Fig. 4 is a cross-sectional view of the tub of Fig. 2
with a stopper disposed therein;
Fig. 5 is a rear elevational view of the one-piece
component system in accordance with the present invention; and
Fig. 6 is a cut-away view of an encapsulated version
of a tub with an overflow assembly in accordance with the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
Fig. 1 i:~ included as an example of a typical prior
art overflow system comprising a plurality of components which
must be assembled and connected to the tub at installation. As
evident from the drawing, the large number of components
requires connection to one another and to the tub at
installation. Time: and labor are involved in fitting and
attaching the piecea together and connecting the assembly to
the tub at installation.
Reference: is now made to Figs. 2, 3, and 4 which
depict a sanitary fixture in the form of a tub 10,
incorporating an overflow system, indicated at 12, constructed
in accordance with a preferred embodiment of the present
invention. Tub 10 includes a shell 14 having a finish side 16
and a non-finish side 18. Shell 14 has a bottom wall 20
integrally formed with side walls 22 and 24 and end walls 26
and 28. Side and end walls 22, 24, 26, and 28 terminate at rim
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29. Shell 14 may be constructed from steel,
fiberglass, polymeric materials and/or composite
materials and methods disclosed in commonly assigned
U.S. Patent Nos. 4,844,944 and 4,84~~,955 to Graefe et
al. and commonly assigned U.S. Patent No. 5,049,433 to
Kuszaj et al.
Finish side 16 may be coat=ed with an enamel
layer. If desired, non-finish side 18 may be coated
with a polymeric material. Suitable polymeric
materials for coating the rigid she-_1 are discussed in
commonly assig:zed U.S. Patent No. 4,664,982 to Genovese
et al., as well as the aforementioned U.S. Patent Nos.
4,844,944, 4,844,955 and 5,049,433.
Overflow system 12 is supported on exterior
non-finish side 18 of shell 14. Bottom wall 20 of
shell 14 includes a drain opening 30 having a lip 32
which permits waste water to drain t:herethrough into a
main drain coupled to drain opening 30 when tub 10 is
installed. End wall 26 of shell 14 includes an
overflow opening 34 proximate rim 29 through which
excess water will flow when water in the tub reaches
the level of the overflow opening. The overflow
opening 34 may be round, oval or other suitable shape.
In accordance with one aspect of the
invention, a onepiece conduit 35 via peripheral flange
36 is adhered to the coated or uncoated side of non-
finish side 18 of shell 14 which thereafter may or may
not be coated with a polymeric material. The conduit 35
as viewed in Fig. 5 is typically trough-shaped and may
be fabricated of. metal, p:Lastic, polymeric material,
A
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SMC (sheet molding compound) or other suitable material. The
shape of the conduit is such that it is formed to fit the
curvature of each particular tub. The first or upper end of
the conduit is configured to cover the overflow opening 34 of
the shell and the second or lower end has a drain aperture 37
corresponding to t:he drain opening 30. Conduit 35 may be
adhered to the shell by an adhesive material such as epoxy, hot
melt, urethane or other similar adhesive material. If the
addition of a polymeric layer is desired, conduit 35 may be
attached to the shell prior to the application of a polymeric
material, becoming encapsulated by the polymeric material, or
it may be attached, to a polymeric layer after the layer has
cured. Fig. 6 shows conduit 35 attached to shell 14 and
encapsulated by polymeric layer 38.
A plug or' stopper 39 is positioned within drain
opening 30 and may be operated by a spring or other suitable
means. Should water in shell 14 reach the level of the
overflow opening 34, water will flow through opening 34,
through conduit 35 and out through aperture 37 of conduit 35,
which, during the installation of the tub, will be coupled to a
main drain pipe in. a well-known manner.
The drain. hardware needed to connect the drain opening
30 to a main drain. may include but is not limited to a
tailpiece 40, washer nut 41, washer 42 and wedge seal 43. The
assembly process at the drain is a simplified operation and
involves placing the tailpiece 40 through the drain hole in the
tub, placing wedge. rubber seal 43 over the bottom of the
tailpiece 40, sliding on the brass washer 42 and tightening the
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8
washer nut 41 to seal the wedge rubber seal 43 against the tub.
The assembly of this hardware is much easier and faster
requiring fewer parts than the conventional method which
requires external piping to connect the overflow and the drain,
as shown in Fig. 1.
Thus, the present invention provides a one-piece
overflow system for a tub which is an integral component of
the tub. It may be bonded to the tub by an adhesive material
without encapsulation thereof or it may be additionally
encapsulated in a plastic material bonded to the under surface
of the tub. The overflow system is adapted to withstand the
heat and pressure exerted during the molding process when the
plastic layer is :bonded in place on the non-finish surface of
the tub.
The single component system of the present invention
reduces the number of components necessary to provide an
overflow drain system, thereby reducing the amount of molding
equipment necessary to manufacture the components. Moreover,
the attachment of the overflow system to the tub at
manufacture reduces and eases the labor involved during
installation of tlZe tub. This is very economical when a large
project requiring the installation of high numbers of units is
involved.
Although illustrative embodiments of the present
invention have been described herein with reference to the
accompanying drawings, it is to be understood that the
invention is not :Limited to those precise embodiments, and
that various other changes and modifications may be effected
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therein by one skilled in the art without departing from the
scope or spirit of the invention.
