Monolithic drain, tooling, and method of manufacturing the same

Abstract

A monolithic drain body including a base wall defining an outlet and a periphery, a side wall extending from the periphery of the base wall to produce an open end opposite the base wall, and a ledge formed into the side wall and extending inwardly therefrom to at least partially enclose a first volume between the ledge, the side wall, and the base wall.

What is claimed is: 
     
         1 . A drain comprising:
 a base wall defining an outlet and a periphery;   a side wall extending from the periphery of the base wall to define an open end opposite the base wall; and   a ledge formed into the side wall and extending inwardly therefrom to at least partially enclose a first volume between the ledge, the side wall, and the base wall, wherein the ledge forms a neck having a first cross-sectional shape, wherein the first volume includes a second cross-sectional shape that is larger than the first cross-sectional shape, and wherein the base wall, side wall, and ledge are formed from a monolithic material.   
     
     
         2 . The drain of  claim 1 , wherein the monolithic material is a piece of sheet material. 
     
     
         3 . The drain of  claim 1 , wherein the monolithic material is formed using a metal spinning technique. 
     
     
         4 . The drain of  claim 1 , wherein the drain further comprises a drain pipe coupled to the outlet and in fluid communication with the first volume, wherein the drain pipe is formed from a second piece of material different than the monolithic material. 
     
     
         5 . The drain of  claim 1 , wherein the drain further includes a top plate coupled to the open end of the side wall, wherein the top plate is formed from a second piece of material different than the monolithic material. 
     
     
         6 . The drain of  claim 1 , wherein the drain defines a drain axis, and wherein at least a portion of the base wall is oblique to the drain axis. 
     
     
         7 . The drain of  claim 1 , wherein the drain defines a drain axis, wherein the base wall has a circular periphery, and wherein the side wall extends axially from the periphery of the base wall. 
     
     
         8 . The drain of  claim 1 , wherein the ledge extends inwardly from the side wall along the entire circumference of the side wall. 
     
     
         9 . The drain of  claim 1 , wherein the first cross-sectional shape is a circle having a first diameter, and wherein the second cross-sectional shape is a circle having a second diameter greater than the first diameter. 
     
     
         10 . A method of manufacturing a drain having a monolithic body, the method comprising:
 providing a die with a first exterior surface;   forming a first monolithic piece of sheet material over the first exterior surface of the die to produce the monolithic body, wherein the monolithic body has an internal volume having a first cross-sectional shape accessed via an aperture having a second cross-sectional shape that is smaller than the first cross-sectional shape; and   removing the die from the internal volume via the aperture.   
     
     
         11 . The method of  claim 10 , wherein the die includes a head unit and at least one die segment removably attached to the head unit, and wherein the head unit and at least one die segment together form the first exterior surface. 
     
     
         12 . The method of  claim 11 , wherein removing the die from the internal volume includes removing the head unit from the internal volume via the aperture and subsequently removing the at least one die segment from the internal volume via the aperture. 
     
     
         13 . The method of  claim 11 , wherein the die segment is one of a plurality of die segments, and wherein the plurality of die segments together form the first cross-sectional shape. 
     
     
         14 . The method of  claim 10 , further comprising forming the first monolithic piece of sheet material over the first exterior surface using a metal spinning process. 
     
     
         15 . The method of  claim 10 , wherein the first cross-sectional shape includes a circle having a first diameter, and wherein the second cross-sectional shape includes a circle having a second diameter smaller than the first diameter. 
     
     
         16 . The method of  claim 10 , further comprising coupling a top plate formed from a second piece of material to the monolithic body. 
     
     
         17 . The method of  claim 10 , further comprising coupling a drain pipe formed from a second piece of material to the monolithic body. 
     
     
         18 . A die having an external surface configured to at least partially form an internal volume, the die comprising:
 a head unit defining a die axis, wherein the head unit includes a first end and a second end opposite the first end;   a first die segment removably coupled to the head unit, wherein the first die at least partially forms the external surface; and   wherein when the first die segment is coupled to the head unit the resulting assembly produces an assembled cross-sectional shape taken normal to the die axis and passing through the first die segment, and wherein the first die segment can be completely detached from the head unit without extending outside the assembled cross-sectional shape during the detachment process.   
     
     
         19 . The die of  claim 18 , wherein the head unit defines a first aperture that is open axially toward the second end, and wherein the first die segment includes a first protrusion configured to be at least partially received within the first aperture. 
     
     
         20 . The die of  claim 18 , wherein the first die segment is one of a plurality of die segments, and wherein when each of the plurality of die segments are attached to the head unit the plurality of die segments completely extend along and enclose the assembled cross-sectional shape.