CROSS-REFERENCE TO RELATED APPLICATION

[0001] This non-provisional application claims the benefit of, and priority from, United States Provisional Application 61/181,726 filed May 28, 2009 and United States Provisional Application 61/184,373 filed June 5, 2009 the contents all of which are incorporated by reference herein in their entirety.

TECHNICAL FIELD

[0002] The present invention relates generally to drain assemblies, and more particularly to drain assemblies incorporating plugs adapted to reduce the transmission of exterior noise into the passenger compartment of an automobile or other transportation vehicle.

BACKGROUND OF THE INVENTION

[0003] Automobiles and other transportation vehicles are configured to protect occupants from the elements. For example, vehicles may be equipped with one or more sunroofs so that passengers may enjoy the experience of open air driving. In the event that the vehicle encounters inclement weather, the sun roof may be closed so as to prevent the introduction of water into the passenger compartment. In order to work effectively in the rain, it is known to equip sun roofs with seals so as to prevent water from leaking into the passenger compartment when the sun roof is in a closed condition. However, the construction of a sunroof may create a depression in the roof of the vehicle that will potentially permit water to accumulate. To prevent the accumulation of water, it is known to provide a vent that allows water to drain away from the depression. The vent is typically connected via a hose to a drain hole in the vehicle body so that the water that might otherwise accumulate may be safely removed from the depression on a continuous basis. In this manner, the opening of the sun roof will not result in a sudden cascade of water onto the occupants of the vehicle. It is also well known to provide transportation vehicles with air conditioning systems that remove moisture from the air during operation. The moisture which is removed from the air typically accumulates in an evaporator case and is removed through a hole in the dash panel by means of a hose connected to a vent in the evaporator case.

[0004] While these methods of removing unwanted water from locations of accumulation are highly functional, they may tend to result in the undesirable side effect of increasing the noise level within the passenger compartment. Specifically, the vents that are used to drain accumulated water away from locations such as the sun roof, air conditioning system, or the like, may provide a conduit for the transmission of noise from the exterior of the vehicle into the passenger compartment. As will be appreciated, a general design goal in most vehicles is to make the passenger compartment as quiet as possible. Typical techniques for achieving reduced noise levels may include the use of sound absorbing materials and seals on various panels including floor panels, dash panels, roof panels and the like. However, transmission openings such as vents and the like extending through the panels substantially reduces the efficacy of the insulation. Accordingly, a continuing need exists to provide an effective drain system to facilitate the removal of accumulated water from various locations in the vehicle which nonetheless dampen the noise entering the vehicle compartment through the vent.

SUMMARY OF THE INVENTION

[0005] In one exemplary construction the present invention provides advantages and alternatives over the prior art by providing a drain assembly adapted for disposition in fluid communication with a point of fluid accumulation. The drain assembly includes a substantially rigid body of hollow construction including an inlet adapted for connection to a hose, tubing, or the like and an outlet downstream from the inlet. A pliable insert plug is disposed within the drain body. The insert plug defines a tortured fluid flow path for transport of the liquid through the drain assembly. The circuitous flow path permits the continuous flow of liquid while nonetheless damping sound transmission in the reverse direction. The insert plug may operate alone or in conjunction with an outer flow-reversing covering. Other exemplary constructions, features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is an exploded schematic view of an exemplary drain assembly according to one embodiment of the present invention;

[0007] FIG. 2 is a schematic perspective view of an exemplary embodiment of a drain assembly illustrating an insert plug disposed at the interior of a drain body;

[0008] FIG. 3 is an elevation perspective view of an exemplary embodiment of an insert plug useful in the drain assembly of FIG. 2 showing the plug cover in a folded out condition;

[0009] FIG. 4 is a view taken generally along line 4-4 in FIG. 3 showing the plug cover in a folded out condition;

[0010] FIG. 5 is a schematic perspective view of the insert plug of FIGS. 3 and 4 with the plug cover in a folded-in latched condition;

[0011] FIG. 6 is a cut-away view of an exemplary drain assembly including a pliable insert plug having a labyrinth flow channel;

[0012] FIG. 7 is a view similar to FIG. 6 illustrating an alternative labyrinth flow channel;

[0013] FIG. 8 illustrates an exemplary configuration for a sound damping insert for disposition within a flow channel at the interior of a drain assembly;

[0014] FIG. 9 illustrates an exemplary configuration for a sound damping insert for disposition within a flow channel at the interior of a drain assembly; and,

[0015] FIG. 10 illustrates an exemplary drain assembly incorporating an interior sound-damping insert adapted for disposition at the interior of a drain assembly.

[0016] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is in no way limited in its application or construction to the details and arrangement of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and of being practiced or being carried out in various other ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description only and should not be regarded as limiting. In this regard, the use of "including," "comprising," and variations thereof should be understood to encompass the items listed thereafter and equivalents, as well as additional items and equivalents thereof.

DETAILED DESCRIPTION OF EMBODIMENTS

[0017] Reference will now be made to the drawings, wherein to the extent possible, like reference numerals designate like elements throughout the various views. An exemplary drain assembly 10 is shown in FIG. 1. In the exemplary embodiment, the drain assembly 10 includes a drain body 12 of a generally rigid material such as injection molded Nylon 6, Nylon 6,6, polyester, polypropylene, polyethylene, polycarbonate or the like. In the illustrated arrangement, the drain body 12 includes an inlet 14 and an outlet 16. The drain body 12 is hollow along its length thereby allowing water or other liquid to flow between the inlet 14 and the outlet 16. As illustrated, in the exemplary configuration the inlet 14 is disposed at an elongated nipple segment 18 which is adapted to be received within a liquid feed tube (not shown) carrying liquid away from an opening in a depression surrounding a sunroof, a fluid reservoir in an air conditioning system, or the like. An elbow segment 20 is disposed rearward of the nipple 18 and acts to direct liquid to the outlet 16. Of course, the presence of the elbow 20 is in no way essential, and the drain assembly 10 may have a substantially straight configuration if desired. In the illustrated arrangement, the drain assembly 10 includes a collar 22 disposed at the base of the elbow 20. Using this arrangement, the nipple 18 and elbow 20 may be extended through an opening in a panel (not shown) with the collar 22 seated against the panel. Of course, any number of other mounting arrangements also may be used.

[0018] As shown, the outlet 16 of the drain assembly 10 may be surrounded by a discontinuous wall structure 26. In the illustrated configuration, the wall structure 26 includes an arrangement of window openings 28 (only one shown) of generally slot- like configuration arranged circumferentially about the wall structure 26 at a position rearward of the collar 22. The wall structure 26 further includes an arrangement of rearwardly projecting legs 30. As shown, the rearwardly projecting legs 30 include outwardly projecting hooks 32. As will be appreciated, the rearwardly projecting legs 30 are relatively flexible and may flex in a spring-like manner relative to the body of the wall structure 26.

[0019] In the illustrated exemplary construction, a plug element 40 is provided for insertion into the outlet 16 of the drain body. In this regard, the plug element 40 is preferably formed of a substantially pliable material such as TPE (thermoplastic elastomer) or the like. In this regard, while the plug element 40 is illustrated as an element independent from the outlet 16, it is likewise contemplated that such a structure may be formed integrally with the outlet 16 of the drain body 12 by techniques such as twin-shot injection molding or the like.

[0020] In the illustrated exemplary construction, the plug element 40 includes a forwardly projecting hub 42 extending away from a circumferential flange 44. In practice, when the plug element 40 is in place, the hub 42 extends towards the base of the elbow 20 with the flange 44 disposed adjacent to the underside of the collar 22 so as to form a substantially fluid-tight seal. In this regard, the plug element 40 is substantially hollow and may receive fluid through an opening at the center of the hub 42.

[0021] In the illustrated configuration, the plug element 40 is hollow at the center and includes an arrangement of radial flow outlets 46 (only one shown) disposed at positions rearward of the flange 44. Thus, liquid entering the plug element 40 through the opening in the hub 42 may pass along an axial flow path and then radially outwardly through the radial flow outlets 46. In this regard, the underside of the plug element 40 facing away from the hub 42 may be either open or closed. [0022] In the exemplary construction, a cover 50 of a generally cup-like construction may be disposed in surrounding relation to the wall structure 26 of the outlet 16. By way of example only, the cover 50 may include arrangement of acceptance openings 52 disposed in a pattern aligned to receive and retain outwardly projecting hooks 32 of complimentary rearwardly projecting legs 30 in snap-fit relation. That is, as the hooks 32 enter the acceptance openings 52 they will flex inwardly and will then snap into place behind the underside of the cover 50 once the insertion is complete.

[0023] In the final assembled condition, the plug element 40 in combination with the segmented wall structure 26 and the cover 50 acts to cause liquid flowing along the drain body 12 and into the opening in the plug to travel in a generally "U" shaped path through the radial flow outlets 46 and out the window openings 28. The cover 50 thus provides a spillway for the expelled fluid and defines an additional barrier to direct flow. As will be appreciated, while liquid such as rainwater or the like entering the inlet 14 of the drain assembly 10 may still be conveyed out of the drain assembly 10, the travel path of that liquid is extremely circuitous including a number of barriers that the liquid must flow around. While this tortured travel path does not adversely affect the gravity fed liquid, the pathway provides an effective barrier to the travel of noise back in a reverse direction through the drain assembly 10. Specifically, since the flow path includes an arrangement of a number of barriers, the sound waves are substantially deadened by blocking surfaces thereby reducing the level of noise transmitted along the assembly towards the passenger compartment.

[0024] While a flow path in which the liquid flows out of the radial flow outlets 46 and then through the window openings 28 may be useful in minimizing noise transmission, it is likewise contemplated that other, more direct flow paths may be used which nonetheless provide substantial benefits. By way of example only, in one alternative practice the plug element 40 may be used to provide a sealing function but the inner walls surrounding the contained axial flow passageway leading to the radial flow outlets 46 are eliminated. Thus, liquid passes directly to the window openings 28 without first traveling through the radial flow outlets 46. As will be appreciated, this arrangement will provide less flow resistance.

[0025] By way of example only, in another alternative practice, liquid may flow directly from the radial flow outlets 46 or through as gap between the bottom of the plug element 40 and the bottom of the wall structure 26 without being forced to reverse back through the window openings 28. As will be appreciated, this arrangement will provide less flow resistance.

[0026] While a structure as illustrated in FIG. 1 which incorporates a cover 50 may be desirable for a number of uses, it is likewise contemplated that configurations may be used which do not incorporate such a cover. By way of example only, and not limitation, FIGS. 2-5 illustrate a drain assembly 110 providing a sound-blocking tortured flow path without a separate applied cover. In this exemplary embodiment, elements corresponding to those previously described are designated by like reference numerals within a 100 series.

[0027] As best illustrated through joint reference to FIGS. 2 and 3, the drain assembly 110 includes a segmented wall structure 126 with an arrangement of slotted window openings 128 disposed about the circumference. A plug element 140 (FIG. 3) is disposed at the interior of the wall structure 126. As illustrated, the plug element 140 includes a central flow passage 160 which accepts liquid from the elbow 120. As shown, the central flow passage 160 includes a pattern of radial flow outlets 146. The radial flow outlets 146 permit fluid entering the flow passage 160 to travel outwardly in a radial direction. The plug element 140 also includes an upper ring 144 defining a flange for disposition against the underside of the collar 122 as previously described. In the illustrated exemplary arrangement, the plug element 140 includes an integral hinging cap 162. As best seen through joint reference to FIGS. 4 and 5, in the illustrated exemplary construction the cap 162 includes a downwardly projecting latch 164 which engages a catch opening 166 on an opposing side of the plug element 140. As shown by the arrow in FIG. 3, during assembly the cap 162 may be rotated from the position shown in FIGS. 3 and 4 to the position shown in FIG. 5 such that the latch 164 engages the catch opening 166 and is held in place. In this position, the cap 162 closes off the end of the central flow passage 160 thereby substantially blocking axial flow through the flow passage 160. Thus, liquid entering the flow passage 160 is caused to be expelled outwardly through the radial flow outlets 146. [0028] In operation, the combination of the plug element 140 and the surrounding segmented wall structure 126 provides fluid passing along the drain assembly 110 to move through a substantially circuitous, tortured flow path as it exits the drain assembly. Specifically, with the exit of the flow passage 160 blocked by the cap 162, liquid entering the flow passage 160 will be caused to travel radially outwardly through the radial flow outlets 146 and then upwardly to the window openings 128 for final expulsion. While such a circuitous tortured flow path does not hinder the transport of gravity fed water or other liquid, it does substantially block sound transmission in the reverse direction due to the sound-deadening properties of the various blocking structures along the flow path. Moreover, the relatively soft character of the plug element 140 which may be formed from TPE or a like material will also aid in dampening any sound transmission.

[0029] In accordance with an exemplary embodiment, a drain assembly may include a sound dampening plug element which incorporates internal damping members arranged in a labyrinth configuration which permits the passage of gravity fed liquid while blocking sound transmission in the reverse direction. By way of example only, FIG. 6 illustrates an exemplary drain assembly 210 wherein elements corresponding to those previously described are designated by like reference numerals within a 200 series. In the illustrated exemplary construction, a plug element 240 is inserted into the drain body 212 such that the interior flow passage 260 of the plug element extends to a position forward of the drain body collar 222. In this arrangement, the plug element 240 may be surrounded by a segmented wall structure 226 as previously described. While the drain assembly 210 may operate substantially as those embodiments described previously, the plug element 240 provides additional sound dampening capability by virtue of the inclusion of projection elements 270 extending inwardly from the walls of the flow passage 260. [0030] According to a potentially preferred practice, the projection elements 270 may extend completely or partially about the inner circumference of the flow passage 260 so as to establish an arrangement of downwardly and inwardly angled flaps which are arranged in a labyrinth pattern to permit water or other liquid to cascade downwardly along the projection elements to the point of final discharge. Specifically, the water or other liquid may pass from one projection element to the next by means of gravity feed and may then exit out of a radial flow outlet as previously described. By way of example only, and not limitation, the projection elements 270 may be integral with the plug element 240 and may be formed from a relatively soft pliable material such as TPE or the like. As will be appreciated, due to the inwardly and downwardly angled arrangement of the projection elements 270 liquid flow in the direction of gravity feed may be maintained without difficulty. However, the projection elements 270 present a series of overlapping barriers to sound transmission in the reverse direction.

[0031] While the downwardly and inwardly angled projection elements illustrated in FIG. 6 may be desirable in many environments of use, it is contemplated that any number of other configurations of projection elements may likewise be used. By way of example only, in FIG. 7, there is illustrated a drain assembly 310 wherein elements corresponding to those previously described are designated by like reference numerals within a 300 series. As will be appreciated, the drain assembly 310 is substantially similar to the configuration in FIG. 6 with the exception that the projection elements 370 have a generally curved configuration with a concave surface facing upwardly so as to contact water or other fluid moving by gravity flow through the drain assembly 310. As will be appreciated, such a structure may facilitate gravity- feed transport of water or other liquid while also providing an effective barrier to sound transmission in the reverse direction.

[0032] In accordance with other embodiments, it is contemplated that inserts may be placed within the flow passage of a plug element or drain body to permit liquid flow while nonetheless blocking sound transmission in the reverse direction. By way of example only, FIG. 8 illustrates an exemplary insert 375 which may extend axially along a flow passage. As shown, in the exemplary construction the insert 375 incorporates projection elements 370 extending radially inwardly at the interior of a perimeter boundary wall 377. In this regard, the outer diameter of the perimeter boundary wall 377 may be configured to substantially conform with the inner diameter of the flow passage into which it is inserted. Inwardly compressible ramped snap elements 385 may be disposed along the outer surface of the perimeter boundary wall 377. Thus, as the insert 375 is moved into place, the snap elements 385 may compress inwardly and then spring into a locked condition behind ledges or other elements at the inner diameter of the flow passage into which it is inserted. The insert 375 is thereby locked into place. Of course, such an insert may also be inserted into the inlet 314 if desired. As will be appreciated, while the insert 375 is illustrated incorporating the projection elements 370 of curved construction, virtually any other construction may likewise be used.

[0033] By way of example only, FIG. 9 illustrates an exemplary insert 480 which may extend axially along a flow passage within a plug element or drain body as previously described. As shown, in the exemplary construction the insert 480 includes a central mounting rod 482 with an arrangement of segmented disks 484 arranged in angled relation to the mounting rod 482. As illustrated, the segmented disks include cut-out zones 486 which are arranged in staggered, alternating position relative to one another at the downwardly angled edge of the disks 484. Thus, water or other liquid may cascade downwardly from one disk to the next with the cut-out zones 486 defining the travel path between the disks. In this regard, the disks 484 may have a cross- sectional diameter which is substantially equivalent to the inner diameter of the flow passage into which the inert 480 is placed. In such an arrangement, the flow of liquid such as water or the like will be exclusively along the flow path defined by the cut-out zones 486.

[0034] As will be appreciated, the insert 480 will permit substantial liquid transport by gravity feed. However, sound transmission in the rearward direction will be substantially precluded. Moreover, such sound dampening properties may be reduced still further by forming the disks 484 from a sound absorbing relatively soft material such as TPE or the like.

[0035] While the inclusion of various sound damping barriers within the outlet of a drain assembly may be useful and desirable in many applications, it is also contemplated that inserts or other sound damping devices may be incorporated at the inlet of a drain assembly to provide sound damping benefits without unduly restricting flow. By way of example only, FIG. 10 illustrates an exemplary drain assembly 510 of a construction as previously described. In this arrangement, an insert 580 is placed into the inlet 514 of the drain body which is thereafter surrounded by a drain hose 595 which feeds water or other liquid into the drain assembly 510. In the illustrated construction, the insert 580 has a generally helical configuration surrounding a mounting rod 582. As will be recognized, in such an arrangement fluid may flow in a screw-like path about the insert. However, sound transmission in the reverse direction will be substantially deadened by the series of blocking barriers presented by the helix construction. Of course, while a simple helix construction is illustrated and may be beneficial, it is likewise contemplated that virtually any other barrier arrangement may be utilized including, without limitation, an arrangement of projection elements as illustrated in FIG. 8, segmented disks as illustrated in FIG. 9 or such other construction as may be desired. Such structures all define types of plug elements which permit fluid to flow while blocking sound transmission in the reverse direction. Of course, the use of an insert at the inlet of a drain assembly may be used either alone or in conjunction with sound-deadening elements at the outlet as previously described.

[0036] Of course, variations and modifications of the foregoing are within the scope of the present invention. Thus, it is to be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art.

[0037] Various features of the invention are set forth in the following claims.