Floor drain

Abstract

A floor drain system includes a generally rectangular drain grate having a plurality of drain apertures, and a drain body, having a circular lower portion defining an outlet and configured to mate with an underdrain structure, and an upper portion defining an inlet configured to receive the drain grate in a frictional fit. The drain body includes an integral grout rim surrounding the inlet, having a knife-tapered top edge, configured to reduce the visibility of the grout rim between the surrounding material and the grate.

1 . A floor drain system, comprising:
 a generally rectangular drain grate having a plurality of drain apertures; and   a drain body, having a circular lower portion defining an outlet and configured to mate with an underdrain structure, and an upper portion defining an inlet, configured to receive the drain grate in a frictional fit, the drain body including an integral grout rim surrounding the inlet, having a knife-tapered top edge, configured to reduce the visibility of the grout rim between the surrounding material and the grate.   
     
     
         2 . A floor drain system in accordance with  claim 1 , wherein the lower portion includes helical threads configured to threadedly interconnect with the underdrain structure, whereby a height of the inlet can be adjusted by rotating the drain body about a vertical axis. 
     
     
         3 . A floor drain system in accordance with  claim 1 , wherein the drain grate is selected from the group consisting of a solid metal grate, and a metal-clad polymer grate. 
     
     
         4 . A floor drain system in accordance with  claim 1 , wherein the drain body comprises a thin-set tray, configured to overlie a circular drain structure therebeneath, and including undercut grout locking features disposed on an outer perimeter of the upper portion, configured to mechanically interlock the drain body with surrounding grout material. 
     
     
         5 . A floor drain system in accordance with  claim 1 , wherein the drain body includes undercut grout locking features disposed on an outer perimeter of the upper portion, configured to mechanically interlock the drain body with surrounding grout material. 
     
     
         6 . A floor drain system in accordance with  claim 5 , wherein the undercut grout locking features are selected from the group consisting of a horizontal undercut edge, and tapered buttresses. 
     
     
         7 . A floor drain system in accordance with  claim 1 , wherein the knife-tapered top edge of the grout rim has a top edge with a minimum thickness of from about from about 0.01″ to about 0.005″. 
     
     
         8 . A floor drain system in accordance with  claim 1 , further comprising a plug, configured to removably fit into the inlet to support the drain body and the grout rim during installation of the floor drain. 
     
     
         9 . A floor drain system in accordance with  claim 1 , further comprising a handle, configured to rotationally interlock with a selected aperture of the drain grate, to allow removal of the grate from the drain body. 
     
     
         10 . A floor drain system in accordance with  claim 1 , further comprising a recess in an inner portion of the inlet, for receiving a hair trap. 
     
     
         11 . A floor drain, comprising:
 a height-adjustable drain body, having a circular lower portion defining an outlet, the lower portion being configured to interconnect to an underdrain structure, and a generally rectangular upper portion defining an inlet, the upper portion including an integral grout rim surrounding the inlet and having a knife-tapered top edge; and   a generally rectangular drain grate, supported by the drain body, having a plurality of drain openings, configured to insert into the inlet with an interference fit, whereby the drain grate is removably secured to the drain body.   
     
     
         12 . A floor drain in accordance with  claim 11 , wherein the drain grate is selected from the group consisting of a solid metal grate, and a metal-clad polymer grate. 
     
     
         13 . A floor drain in accordance with  claim 11 , wherein the grout rim includes a knife-tapered top edge with a thickness of from about from about 0.01″ to about 0.005″ and an outer face having a taper of about 30°. 
     
     
         14 . A floor drain in accordance with  claim 11 , further comprising a plug, configured to removably fit into the inlet to support the drain body and the grout rim during installation of the floor drain. 
     
     
         15 . A floor drain assembly, comprising:
 a drain body, having a generally rectangular upper portion defining an inlet aperture, and a circular lower portion defining an outlet in fluid communication with the inlet aperture, the lower portion having helical threads configured to threadedly interconnect with an underdrain, whereby a height of the inlet can be adjusted by rotating the drain body about a central axis, and the upper portion including an integral grout rim surrounding the inlet and having a knife-tapered top edge;   a generally rectangular drain grate, having a plurality of drain openings, surrounded by the grout rim and supported by the drain body; and   an underdrain attached to the outlet of the drain body.   
     
     
         17 . A floor drain in accordance with  claim 15 , wherein the drain body includes undercut grout locking features disposed on an outer perimeter of the upper portion, configured to mechanically interlock the drain body with surrounding grout material. 
     
     
         18 . A floor drain in accordance with  claim 15 , wherein the knife-tapered top edge of the grout rim has a top edge with a minimum thickness of from about from about 0.01″ to about 0.005″. 
     
     
         19 . A floor drain in accordance with  claim 15 , wherein the drain grate is selected from the group consisting of a solid metal grate, and a metal-clad polymer grate. 
     
     
         20 . A floor drain in accordance with  claim 15 , further comprising a T-handle grate removal tool, configured to insert through a selected opening in the drain grate, to facilitate removal of the drain grate from the drain body.