Monolithic drain, tooling, and method for making 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 method of manufacturing a drain having a monolithic body, the method comprising:
 forming a first monolithic piece of sheet material over a first exterior surface of a 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.   
     
     
         2 . The method of  claim 1 , 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. 
     
     
         3 . The method of  claim 2 , wherein a torque pin removably attaches at least one die segment to the head unit. 
     
     
         4 . The method of  claim 2 , wherein the head unit and at least one die unit are rotationally locked together when removably attached. 
     
     
         5 . The method of  claim 2 , 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. 
     
     
         6 . The method of  claim 5  wherein at least one of the die segments is a different size that the other segments, and the at die segments are removed from in order of size, from smallest to largest. 
     
     
         7 . The method of  claim 2 , 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. 
     
     
         8 . The method of  claim 1 , further comprising forming the first monolithic piece of sheet material over the first exterior surface using a metal spinning process. 
     
     
         9 . The method of  claim 1 , 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. 
     
     
         10 . The method of  claim 1 , further comprising coupling a top plate formed from a second piece of material to the monolithic body. 
     
     
         11 . The method of  claim 1 , further comprising coupling a drain pipe formed from a second piece of material to the monolithic body. 
     
     
         12 . 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.   
     
     
         13 . The die of  claim 12 , 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. 
     
     
         14 . The die of  claim 13 , wherein the head unit defines a second aperture that is open axially towards the second end and is radially offset from the first aperture, and wherein the first die segment includes a second protrusion configured to be at least partially received within the first aperture. 
     
     
         15 . The die of  claim 12 , 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. 
     
     
         16 . The die of  claim 15 , wherein one or more of the plurality of die segments are attached to the head unit via one or more locking pins. 
     
     
         17 . The die of  claim 15 , wherein the external surface includes a first portion with a first outer diameter, a second portion extending axially from the first portion with a second outer diameter less than the first outer diameter, and a third portion extending axially from the second portion opposite the first portion with a third outer diameter that is greater the second outer diameter. 
     
     
         18 . The die of  claim 15 , wherein each of the plurality of die segments is identical. 
     
     
         19 . The die of  claim 15 , wherein at least one of the plurality of die segments includes parallel side walls. 
     
     
         20 . The die of  claim 15 , wherein the head unit and plurality of die segments are rotationally locked to each other.