Adaptable shower pan system

An adaptable shower pan includes: a floor plate with a convex, or flat and level, upper surface; a bottom pan, including a bottom structure with a drainage aperture, and optionally an elongated drainage canal that leads from a drainage center to the drainage aperture; a plate support structure of support ribs; a side structure; and a front structure; such that a drainage gap forms on all sides of the floor, such that the bottom pan is watertight to allow water to drain omnidirectionally from all sides of the upper surface of the floor plate, via the drainage gap, to the drainage aperture.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Non-Provisional application Ser. No. 15/852,535, filed Dec. 22, 2017; which is hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to the field of shower pans, and more particularly to methods and systems for shower pans with a flat and level floor area and features for convenient and adaptable installation.

BACKGROUND OF THE INVENTION

Various well-known methods and devices have been developed to ensure watertight installation of showers. However most modern shower installation techniques require a drain in a central location, which can be both inconvenient and cosmetically undesirable.

Some modern shower designs attempt to shift a drain location to a single side, referred to as a linear or trough drain type system. These systems rely on a sloped floor surface, which may be uncomfortable in use.

As such, considering the foregoing, it may be appreciated that there continues to be a need for novel and improved devices and methods for shower pans.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the present invention, wherein in aspects of this invention, enhancements are provided to the existing model of shower pan designs.

In an aspect, an adaptable shower pan system can include

    • a) a floor plate, which can be a convex or flat and level piece, that is installed such that water drains from all sides of the floor plate;
    • b) a bottom pan, which can also be called a catch basin, the bottom pan including:
      • a bottom structure with a drainage aperture, such that the bottom structure can rest on a floor structure, wherein the bottom structure is configured with a structure surface that slopes toward the drainage aperture; and
      • a plate support structure, which can be positioned on the structure surface of the bottom structure, such that the plate support structure comprises a plurality of flat upper contact surfaces, such that the floor plate can rest stably on the plate support structure, such that the plate support structure is configured to allow water to drain from outer sides of the structure surface to the drainage aperture;
    • c) a side structure, which encloses wall sides of the bottom pan; and
    • d) a front structure, which encloses a front of the adaptable shower pan system;
    • wherein the floor plate is smaller than the bottom pan, such that a drainage gap is formed on all sides of the floor plate, between the floor plate and a combination of the side and front structures;
    • such that the side and front structures are connected around an outer edge of the bottom pan to form a watertight assembly;
    • such that water can drain from a floor surface of the floor plate, via the drainage gap to the drainage aperture.

In a related aspect, the floor plate can be rectangular, and the side structure include:

    • a) a left side member;
    • b) a rear side member, such that a first end of the rear side member can be substantially perpendicularly connected to a second/rear end of the left side member; and
    • c) a right side member, such that a second/rear end of the right side member can be substantially perpendicularly connected to a second end of the rear side member.

In another related aspect, the support structure can further include a plurality of support ribs, such that a height of each support rib increases from an outer end to an inner end, such that upper surfaces of the support ribs are flat and form a flat plane on which the floor plate is configured to be stably positioned.

In yet a related aspect:

    • a) the left side member can be an elongated member, comprising:
      • a first horizontal elongated piece; and
      • a first vertical elongated piece, which is perpendicularly connected to the first horizontal elongated piece, along a left edge of the first horizontal elongated piece;
      • a first rectangular end piece, which is connected to rear ends of the first horizontal and vertical elongated pieces;
    • b) the right side member can be an elongated member, comprising:
      • a second horizontal elongated piece; and
      • a second vertical elongated piece, which is perpendicularly connected to the second horizontal elongated piece, along a right edge of the second horizontal elongated piece;
    • c) the rear side member can be an elongated member, comprising:
      • a third horizontal elongated piece;
      • a third vertical elongated piece, which is perpendicularly connected to the third horizontal elongated piece, along a rear edge of the third horizontal elongated piece.

In yet another related aspect, the bottom pan can include a plurality of support connectors, which are attached to top sides of the support ribs, such that each support connector provides a flat support area for the floor plate, such that each support connector comprises:

    • a) a top support plate with a top surface that is configured as the flat support area;
    • b) a first connector flange that is perpendicularly connected along a bottom of the top support plate;
    • c) a second connector flange that is perpendicularly connected along a bottom of the top support plate;
    • wherein the first and second connector flanges are parallel and mounted side by side with an opening between the first and second connector flanges, such that the support connector is configured to slide firmly onto a support rib, with a part of a support rib inside the opening.

In a related aspect, the bottom structure can further include a flat central area, which is configured to allow a customized location of the drainage aperture, such that the drainage aperture is cut in the flat central area to match a specific location of a drain in a floor, whereby the adaptable shower pan system is configured to be adaptable to varying locations of the drain in the floor.

In yet another related aspect, the bottom structure can further include:

    • an elongated drainage canal, which can extend from a drainage center of the bottom structure to the drainage aperture;
    • such that water flows from all sides down the structure surface of the bottom structure to the drainage center and via the drainage canal to the drainage aperture.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective exploded view of part of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 1B is a perspective view of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 1C is a top view of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 2A is a top view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 2B is a cross-sectional view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 2C is a top view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 2D is a top view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 3A is a perspective view of a side structure of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 3B is a perspective exploded view of parts of a side structure of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 3C is a perspective view of a side structure of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 3D is a perspective exploded view of parts of a side structure of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 4A is a perspective exploded view of part of an adaptable shower pan system configured for corner installation, according to an embodiment of the invention.

FIG. 4B is a perspective view of an adaptable shower pan system configured for corner installation, according to an embodiment of the invention.

FIG. 5A is a perspective exploded view of part of an adaptable shower pan system with support connectors, according to an embodiment of the invention.

FIG. 5B is a top perspective view a support connector of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 5C is a bottom perspective view a support connector of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 5D is a bottom view of a floor plate with permanently attached support connectors, according to an embodiment of the invention.

FIG. 5E is a bottom view of a floor plate with permanently attached support connectors, removably positioned on support ribs of a bottom pan, according to an embodiment of the invention.

FIG. 6A is a top view of a bottom pan with extension blocks added, according to an embodiment of the invention.

FIG. 6B is a front view of a bottom pan with extension blocks added, according to an embodiment of the invention.

FIG. 7A is a top view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 7B is a cross-sectional view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 8A is a perspective exploded view of part of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 8B is a perspective view of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 9A is a perspective top view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 9B is a perspective bottom view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 9C is a perspective bottom view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 9D is a perspective top view of part of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 9E is a perspective top view of part of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 10A is a perspective top view of part of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 10B is a perspective bottom view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 11A is a perspective top view of part of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

FIG. 11B is a perspective bottom view of a bottom pan of an adaptable shower pan system, according to an embodiment of the invention.

 DETAILED DESCRIPTION

Before describing the invention in detail, it should be observed that the present invention resides primarily in a novel and non-obvious combination of elements and process steps. So as not to obscure the disclosure with details that will readily be apparent to those skilled in the art, certain conventional elements and steps have been presented with lesser detail, while the drawings and specification describe in greater detail other elements and steps pertinent to understanding the invention.

The following embodiments are not intended to define limits as to the structure or method of the invention, but only to provide exemplary constructions. The embodiments are permissive rather than mandatory and illustrative rather than exhaustive.

In the following, we describe the structure of an embodiment of an adaptable shower pan system 100 with reference to FIG. 1, in such manner that like reference numerals refer to like components throughout; a convention that we shall employ for the remainder of this specification.

In an embodiment, as shown in FIGS. 1A and 1B, an adaptable shower pan system 100 can include:

    • a) a floor plate 110, which can be a flat piece, which as shown can be rectangular, such that the floor plate 110 has a flat and level upper surface 112;
    • b) a bottom pan 120, including:
      • a bottom structure 130 with a drainage aperture 136, such that the bottom structure 130 is configured to rest on a floor structure 180 with a floor drain 182, wherein the bottom structure 130 is configured with a structure surface 134 that slopes toward the drainage aperture 136; and
      • a plate support structure 140, which is positioned on (i.e. connected to or molded as part of) the structure surface 134 of the bottom structure 130, such that the plate support structure 140 has flat upper contact surfaces 142, such that the floor plate 110 can rest stably on the plate support structure 140, such that the plate support structure 140 is configured to allow water 190 to drain 192 from outer sides of the structure surface 134 to the drainage aperture 136;
    • c) a side structure 150, which is connected to/encloses wall sides of the bottom pan 120, which as shown in FIGS. 1A and 2A can be left, right and rear sides 162, 164, 166 of the bottom pan 120, such that the side structure 150 includes:
      • a left side member 152;
      • a rear side member 156, such that a first/left end 157 of the rear side member 156 is perpendicularly connected to a rear/distal end 153 of the left side member 152; and a right side member 154, such that a second/rear/distal end 155 of the right side member 154 is perpendicularly connected to a second/right end 158 of the rear side member 156; and
      • wherein the left, rear, and right side members 152, 156, 154 can be connected, as shown in FIGS. 1B and 3A, to form a watertight side structure; and
    • d) a front structure/member 160, also referred to as a dam 160, which can be a straight piece 160, which is connected to a front side 168 of the bottom pan 120, such that the front structure/member 160 encloses a front/entry of the adaptable shower pan system 100;
    • wherein the floor plate 110 is slightly smaller than the bottom pan 120, such that a drainage gap 124 forms on all sides of the floor plate 110, between the floor plate 110 and the combination of the left side, rear side, right side, and front members 152, 154, 156, 160 and the floor plate 110;
    • such that, as shown in FIG. 1B, the side and front structures 150, 160 are connected around an outer edge 122 of the bottom pan 120 (i.e. connected around and to respectively rear, side, and front edges of the bottom pan 120) to form a watertight assembly, such that water 190 can drain 192 from a floor surface 112 of the floor plate 110, such that water drains omnidirectionally on all sides of the floor plate 110, via the drainage gap 124 to the drainage aperture 136.

In a related embodiment, as shown in more detail in FIGS. 2A and 2B, the support structure 140 can include a plurality of elongated support ribs 242 that are configured in a substantially circular/star shaped pattern around the drainage aperture 136, such that each support rib is configured to extend from the drainage aperture in a perpendicular direction relative to a periphery of the drainage aperture, such that each support rib points in a direction toward a drainage center 132, 932 of the bottom structure 130, which as shown can be a location of the drainage aperture 136; such that a height 292 of each support rib 242 increases from an outer end 294 to an inner end 296 of each support rib 242, such that upper surfaces 298 of the support ribs 242 are flat and form a flat plane 212 on which the floor plate 110 can rest/be positioned stably.

In other related embodiments, as shown in FIGS. 7A and 7B, a location of the drainage aperture 736 of a bottom pan 720 can vary, such that the drainage aperture 736 may be positioned to the right (as shown), left, front or center, or towards a corner, such that a support structure 740 can include a plurality of elongated support ribs 742 that are configured in a substantially circular/star shaped pattern around the drainage aperture 736, such that a height 792 of each support rib 742 increases from an outer end 794 to an inner end 796 of each support rib 742, such that upper surfaces 798 of the support ribs 742 are flat and form a flat plane 712 on which the floor plate 110 can rest/be positioned stably.

Thus, in various related embodiments, the finished/installed shower floor 110 is completely level, whereas previous conventional shower floor systems slope in some manner towards the drain, depending on location of the drain.

In some embodiments, the adaptable shower pan system 100 can be configured without a dam/front structure/member 160, which for example can be aesthetically pleasing, and can allow for wheel chair access. In such embodiments, the floor surface 112 of the floor plate 110 can be installed at the same level as surrounding tiles in the bathroom, to provide convenient access. The bathroom tiles can be cantilevered over the bottom pan 120, i.e. mounted to overlap slightly over front edges of the bottom pan 120, such that the drainage gap 124 remains open in the front, but can be navigated over with ease by a user in a wheelchair.

In related embodiments, the floor plate 110 can be made from:

    • a) a plastic material, such as ABS plastic, and for example include a textured surface;
    • b) a hard rubber material;
    • c) a natural stone material, such as granite;
    • d) an engineered stone material, such as engineered quartz or cultured marble; or
    • e) other suitable manmade or artificial materials, including porcelain.

In related embodiments, FIG. 2C shows a bottom pan 210c wherein the support structure 140 can be support pillars 243 or elongated short ribs 244, such that upper surfaces 298 of the support pillars/short ribs 243, 244 are flat and form a flat plane 212 on which the floor plate 110 can rest/be positioned stably.

In other related embodiments, the floor plate 110 can be manufactured as one single piece, as shown in FIGS. 1A and 1B, such as made from one cut or molded slab, or it can be assembled from a plurality of tiles 114 or bricks 114, or other plate parts 114, such as shown in FIG. 1C.

In related embodiments, the dam/front structure/member 160 can be made from:

    • a) a plastic material, such as ABS plastic, and for example include a textured surface;
    • b) a hard rubber material;
    • c) a natural stone material, such as granite;
    • d) an engineered stone material, such as engineered quartz or cultured marble; or
    • e) other suitable manmade or artificial materials.

In related embodiments, the bottom pan 120, can be made as one single piece, for example as a single molded plastic or hard rubber piece, a single pressed/shaped plastic or metal piece,

In another related embodiment, as shown in FIGS. 3A and 3B, the side structure 150 can comprise L-shaped members, such that the side structure can be called an L-channel vertical moisture barrier 150, such that:

    • a) the left side member 152 can be an elongated I-shaped member 310, which includes:
      • i. a first horizontal elongated piece 312;
      • ii. a first vertical elongated piece 314, which is perpendicularly connected to the first horizontal elongated piece 312, along a left edge 362 of the first horizontal elongated piece 312; and
      • iii. a first rectangular end piece 316, which is connected to rear/distal ends 366 of the first horizontal and vertical elongated pieces 312, 314;
    • b) the right side member 154 can be an elongated I-shaped member 320, which includes:
      • i. a second horizontal elongated piece 312;
      • ii. a second vertical elongated piece 314, which is perpendicularly connected to the second horizontal elongated piece 312, along a right edge 364 of the second horizontal elongated piece 312; and
      • iii. a second rectangular end piece 316, which is connected to rear/distal ends 367 of the second horizontal and vertical elongated pieces 312, 314; and
    • c) the rear side member 156 can be an elongated I-shaped member 330, including:
      • i. a third horizontal elongated piece 312; and
      • ii. a third vertical elongated piece 314, which is perpendicularly connected to the third horizontal elongated piece 312, along a distal/rear edge 368 of the third horizontal elongated piece 312; and
    • such that the left, rear, and right side members 152, 156, 154 can be connected together, such that the side structure is I-shaped.

In a further related embodiment, as shown in FIG. 3B, left and right side members 152, 154 can be made from a one sheet piece, by folding an I-shaped member 320 that has a lateral cut 382 through the horizontal elongated piece 322, such that a distal/rear end 334 of the vertical elongated piece 324 can be folded around a lateral fold 384 of the vertical elongated piece 314 that is connected to the lateral cut 382, such that an distal/rear flap 332 of the horizontal elongated piece 312 folds 390 onto (typically under or alternatively over) the horizontal elongated piece 312 when the distal/rear end 334 of the vertical elongated piece 314 is folded such that the distal/rear end 334 of the vertical elongated piece 314 forms an end piece 316.

In related embodiments, the left, rear, and right side members 152, 156, 154 can be glued or welded together, or connected with other methods of permanent bonding. Excess caulk, glue, or padding, such as plastic padding, may be used to seal gaps in non-visible locations, such as between the bottom pan 120 and the side structure 150.

In another related embodiment, as shown in FIGS. 3C and 3D, the side structure 350 can comprise L-shaped members, such that:

    • a) the left, right, and rear side members 352, 354, 356 can each comprise an elongated I-shaped member, including a horizontal elongated piece 342 with a perpendicularly connected vertical elongated piece 344.

In a further related embodiment, as shown in FIGS. 3C and 3D, the side structure 350 can further comprise v-shaped brackets 372 or capped v-shaped brackets 374, to help seal the rear corners of the side structure 350.

In another embodiment, as shown in FIGS. 4A and 4B, an adaptable shower pan system 400 can be configured for corner installation, such that the adaptable shower pan system 400 can include:

    • a) a floor plate 410, which can be a flat and level piece, which as shown can be substantially triangular, for example with a curved front/entry side;
    • b) a bottom pan 420, including:
      • a bottom structure 430 with a drainage aperture 436, such that the bottom structure 430 is configured to rest on a floor structure 180, wherein the bottom structure 430 is configured with a structure surface 434 that slopes toward the drainage aperture 436; and
      • a plate support structure 440, which is positioned on the structure surface 434 of the bottom structure 430, such that the plate support structure 440 has flat upper contact surfaces, such that the floor plate 410 can rest stably on the plate support structure 440, such that the plate support structure 440 is configured to allow water 190 to drain 192 from outer sides of the structure surface 434 to the drainage aperture 436;
    • c) a side structure 450, which is connected to/encloses wall sides of the bottom pan 420, which as shown in FIG. 4A can be first and second sides of the bottom pan 420, such that the side structure 450 includes:
      • a first side member 452; and
      • a second side member 454;
      • wherein the first and second side members 452, 454 are perpendicularly connected;
      • wherein first and second side members 452, 454 can be assembled, as shown in FIG. 4B, to form a watertight side structure; and
    • d) a front structure/member 460, also referred to as a dam 460, which encloses/is connected to a front/entry of the adaptable shower pan system 400, such that the front member 460 can be straight or curved, (here shown curved);
    • wherein the floor plate 410 is slightly smaller than the bottom pan 420, such that a drainage gap 424 forms on all sides of the floor plate 410, between the first side, second side, and front members/structure 452, 454, 460 and the floor plate 410;
    • such that, as shown in FIG. 4B, the adaptable shower pan system 400 forms a watertight assembly, such that water 190 can drain 192 from a floor surface 412 of the floor plate 410, via the drainage gap 424 to the drainage aperture 436.

In a related embodiment, as shown in FIG. 2B, a structure cavity 260 under the structure surface 134 of the bottom structure 130 can be filed with a foam material 262, such as an extruded closed or open cell polyethylene foam 262, which can be a rigid foam 262, in order to provide structural support for the bottom pan 120. In other embodiments, there may be no structure cavity, such that this part of the bottom structure 130 is a solid material, such as solid plastic.

In another related embodiment, as shown in FIGS. 5A, 5B, and 5C, the bottom pan 120 can further include a plurality of support connectors 510, also called t-channel connectors 510, which each are configured to attach to top sides of the support ribs 242 to provide a flat support area 524 for the floor plate 110, such that each support connector 510, as shown in FIGS. 5B and 5C, includes:

    • a) a top support plate 520, such that a top surface 522 is configured to be the flat support area 524;
    • b) a first connector flange 531 that is perpendicularly connected along a bottom of the top support plate 520;
    • c) a second connector flange 532 that is perpendicularly connected along a bottom of the top support plate 520;
    • wherein the first and second connector flanges 531, 532 are parallel and mounted side by side with an opening 534 between, such that the support connector 510 is configured to slide firmly onto a support rib 242, with a part of the support rib 242 inside the opening 534;
    • such that a bottom of the floor plate 110 can be adhered to the support connectors 510 with silicone caulking or other water proof acceptable adhesive.

In a further related embodiment, as shown in FIG. 5D, the support connectors 510 can be permanently adhered to a bottom of the floor plate 110 with a predetermined position of the support connectors 510, such that the floor plate is removably positionable on the support ribs 242 in a fixed position, as shown in FIG. 5E (with hidden/invisible parts shown in dotted lines), such that there is a uniform drainage gap 124 on all sides of the floor plate 110, such that the drainage gap 124 has a substantially uniform width 582, 584, 586, 588;

which can be accomplished by an installation method wherein the support connectors 510 can be strategically placed upon the support ribs, dependent upon if a single plate or multiple plates or tiles are going to be used in the shower floor application. An adhesive 528, such as a silicone adhesive 528, can be applied to a top surface 522 of top support plates 520 of each support connector 510. The floor plate 110 or plates 110 are then set upon the support connectors 510. While the silicone adhesive is still fresh/adjustable the floor plate 110 or plates 110 can be evenly adjusted, to have a uniform drainage gap 124 on all sides of the floor plate 110, such that all outside perimeter sides of the plate/plates are equal distance away from the shower walls and front dam leaving an even opening around the perimeter of the floor for the shower water to drain. The floor plate 110 can then be left to adhere firmly to the support connectors 510. Once adhered the floor plate 110 can be lifted out for access to the drain. The connector flanges now firmly affixed are permanently positioned such that the floor plate 110 can only be placed back exactly as it was originally installed with the uniform drainage gap 124 around the perimeter. Note that relative dimensions of parts, including support connecters 510, are for illustrative purposes only. Support connecters 510 may in some embodiments be relatively smaller (and in some case larger) than shown.

In a related embodiment, as shown in FIG. 2D, the bottom structure 210d can be configured with a flat central area 238, which is configured to allow a customized location of the drainage aperture 136, such that a drainage aperture 136 can be cut in the flat central area 238 to match a specific location of a drain in a floor, whereby the adaptable shower pan system 100 is configured to be adaptable to varying locations of a drain in the floor.

In a related embodiment, as shown in FIGS. 6A and 6B, the adaptable shower pan system 600 can further include a plurality of extension blocks 612, 614, 616 that can be positioned on a rear of, and optionally at least one side of the bottom pan 120, such that the extension blocks are level with outer edges of the bottom structure 210d. The drainage aperture 636 is here shown as rectangular.

In a further related embodiment, the adaptable shower pan system 600 can further include:

    • a) a rear extension block 616, which is connected to a rear side of the bottom pan 120;
    • b) a left side extension block 612, which is connected to a left side of the bottom pan 120; and
    • c) a right side extension block 614, which is connected to a right side of the bottom pan 120;
    • such that the side structure 150, 450, 650 is mounted on outer sides of the bottom pan 120 extended with the extension blocks 612, 614, 616.

In related embodiments, the extension blocks 612, 614, 616 can allow the adaptable shower pan system 100 to be extended beyond its stock size. The extension blocks 612, 614, 616 can be extruded rectangularly, and made of the same material the bottom structure 210d and side structure 150, 450, 650 are made of. The extension blocks 612, 614, 616 can be the same height as the bottom pan's 120 highest point. The extension blocks 612, 614, 616 can be solid or foam filled, and for example made in 12″ width and 8′ length.

Thus, in related embodiments, when the side structure/L-channel vertical moisture barrier 150, the bottom pan 120, and optionally extension blocks 612, 614, 616 can be fitted for the application, and once adhered together create a single monolithic watertight structure that is impervious to moisture penetration. In some embodiments, the bottom pan 120, the side structure/L-channel vertical moisture barrier 150, the floor plate 110, and extension blocks extension blocks 612, 614, 616 can all be made of the same type of plastic material, such as ABS or PVC, and adhered together with an appropriate adhesive.

In related embodiments, as shown in FIG. 9A, the bottom pan 120 920 is modifiable and can be shortened or lengthened/modified to fit into custom or uncommon spaces and shapes. Similarly, the side structure/L-channel vertical moisture barrier 150 may be adapted to fit the size of a modified bottom pan 120, thereby allowing for a design flexibility that is not available with previous premade shower pan systems. FIG. 9A shows example modifications of the bottom pan 920, with a rounded front edge 962 and a shortened side 964 (each shown in dotted line), that each (separately or in combination) can be cut through the bottom pan 920 to modify a shape and/or resize the bottom pan 920. After (and sometimes before) modification, a top of outer ends of the support ribs 142 may not be flush with outer edges of a bottom structure 930 of the bottom pan 920 (i.e. there may be a height difference), but the top of the support ribs 142 remain flat and level.

In related embodiments, the floor plate 110 can be rectangular, triangular, round or any custom shape, with corresponding side structure/L-channel vertical moisture barrier 150 and bottom pan 120, which can both have an irregular shape, to match with a particular wall shape for installation.

There are four common drain placement areas with the center point of the shower floor being the most common. Next common is to the left or to the right wall of the shower and lastly in one of the corners of the shower. The adaptable shower pan system 100 works for all four drain placements. Often in remodel applications the location of the drain is in an odd location or a few inches off of where the premade drain holes of standard pan systems are located. In order to facilitate such oddly placed drains a plumber must be brought in to relocate the drain to match with the premade pan. The adaptable shower pan system 100 being scalable/modifiable/adjustable eliminates the need for a plumber.

In an embodiment, as shown in FIGS. 8A and 8B, an adaptable shower pan system 800 can include:

    • a) a floor plate 810, which as shown can be rectangular, such that the floor plate 110 has a convex upper surface 812, which for example can be a segment of a sphere, ellipsoid, or a convex paraboloid surface; such that the convex upper surface 812 has a highest point 814, within a central portion 816 of the convex upper surface 812, wherein the highest point 814 can be in a center 814 of the convex upper surface 812. The convex upper surface 812 may provide improved flow of water in directions away from the highest point 814, such that water 190 flows uniformly toward all sides of the floor plate 810, and may further be pleasant to stand on for a user of the adaptable shower pan system 800;
    • b) a bottom pan 120, including:
      • a bottom structure 130 with a drainage aperture 136, such that the bottom structure 130 is configured to rest on a floor structure 180 with a floor drain 182, wherein the bottom structure 130 is configured with a structure surface 134 that slopes toward the drainage center 132; and
      • a plate support structure 140, which is positioned on (i.e. connected to or molded as part of) the structure surface 134 of the bottom structure 130, such that the plate support structure 140 has flat upper contact surfaces 142, such that the floor plate 810 can rest stably on the plate support structure 140, such that the plate support structure 140 is configured to allow water 190 to drain 192 from outer sides of the structure surface 134 to the drainage center 132;
    • c) a side structure 150, which is connected to/encloses wall sides of the bottom pan 120, which as shown in FIGS. 1A and 2A can be left, right, and rear sides 162, 164, 166 of the bottom pan 120, such that the side structure 150 includes:
      • a left side member 152;
      • a rear side member 156, such that a first/left end 157 of the rear side member 156 is perpendicularly connected to a rear/distal end 153 of the left side member 152; and
      • a right side member 154, such that a second/rear/distal end 155 of the right side member 154 is perpendicularly connected to a second/right end 158 of the rear side member 156; and
      • wherein the left, rear, and right side members 152, 156, 154 can be connected, as shown in FIGS. 1B and 3A, to form a watertight side structure; and
    • d) a front structure/member 160, also referred to as a dam 160, which can be a straight piece 160, which is connected to a front side 168 of the bottom pan 120, such that the front structure/member 160 encloses a front/entry of the adaptable shower pan system 800;
    • wherein the floor plate 810 is slightly smaller than the bottom pan 120, such that a drainage gap 124 forms on all sides of the floor plate 810, between the floor plate 810 and the combination of the left side, rear side, right side, and front members 152, 154, 156, 160 and the floor plate 810;
    • such that, as shown in FIG. 1B, the side and front structures 150, 160 are connected around an outer edge 122 of the bottom pan 120 to form a watertight assembly, such that water 190 can drain 192 from the convex upper surface 812 of the floor plate 810, such that water drains omnidirectionally on all sides of the floor plate 810, via the drainage gap 124 to the drainage aperture 136.

In a further related embodiment, as shown in FIGS. 9D and 11A the bottom structure 930 can further include an elongated drainage canal 933, 1133, which extends from a drainage center 932 of the bottom structure 930 to a drainage aperture 936, 1136, such that the elongated drainage canal 933, 1133 can either include:

    • a) a penetrating cutout 931, which penetrates through the bottom structure 930, as shown in FIGS. 9A and 9B, such that an initial portion of the penetrating cutout 931 is closed with a sealing plate 938, which is glued to a bottom side of the bottom structure 930, as shown in FIGS. 9C and 9D, such that the initial portion is sealed, such that a final portion 936 of the penetrating cutout 931 remains open to form the drainage aperture 936; or
    • b) a non-penetrating cutout 1031, which can be an elongated indentation 1031 of an upper surface of the bottom structure 1030, such that the elongated indentation does not penetrate through the bottom structure 930, as shown in FIGS. 10A and 10B, such that a drainage aperture 936 can be formed by drilling through a bottom 1035 of the non-penetrating cutout 1031, to form a drainage aperture 1136, as shown in FIGS. 11A and 11B, such that a bottom of the elongated indentation 1031 comprises the drainage aperture 936. The drainage aperture 1136 can as shown be positioned in an outer end of the non-penetrating cutout 1031, but can alternatively be positioned anywhere in the bottom of the non-penetrating cutout 1031, in a specific alternative position 1137 to match with a specific drainage position of the floor drain 182, as shown in FIGS. 11A and 11B;
    • such that water flows from all sides down a surface of the bottom structure 130 to the drainage center and flow via the elongated drainage canal 933, 1133 to the drainage aperture 936, 1136. As is apparent from FIGS. 9D, 9E, and 11A. some water 190 may flow directly into the elongated drainage canal 933, 1133 at an outer area of the elongated drainage canal 933, 1133 away from the drainage center 932, 1032 and then into the drainage aperture 936, 1136.

In related embodiments, the elongated drainage canal 933, 1133, can extend from a drainage center 932 of the bottom structure 930 to a drainage aperture 936, 1136 in various directions, for example as shown extending to a left, but alternatively to a right, rear, or front, or at an angle, in order to accommodate an anticipated or known location of a floor drain 182, such that the drainage aperture 936, 1136 can be connected with a watertight connection to the floor drain 182, using conventional plumbing methods.

In further related embodiments, the elongated drainage canal 933, 1133 can be premanufactured, partially manufacture for final onsite customized, or custom manufactured onsite according to specific dimension of the installation.

In a first partial manufacturing example embodiment, a bottom pan 920 can be provided with a partially manufactured elongated drainage canal 933 as a penetrating cutout 931 without a sealing plate 938, such that a sealing plate 938 can be applied onsite to leave a drainage aperture 936 exposed. The sealing plate 938 can be applied covering only an initial portion of the penetrating cutout 931, as shown in FIG. 9D, or alternatively the sealing plate 938 can cover the entire penetrating cutout 931, such that the drainage aperture 936 is drilled through the sealing plate 938 at a predetermined location to match with a location of a floor drain 182, as shown in FIG. 9E.

In a second partial manufacturing example embodiment, a bottom pan 920 can be provided with a partially manufactured elongated drainage canal 933 as a non-penetrating cutout 1031 without a drainage aperture 1036, such that a drainage aperture 1036 can be drilled onsite in a selected position in a bottom 1035 of the non-penetrating cutout 1031 to match with a location of a floor drain 182.

In a custom manufacturing example embodiment, an elongated drainage canal 933 1133 can be manufactured onsite by notching/routing/cutting out a penetrating cutout 931 at the installation site and applying a sealing plate 938, or by notching/routing/cutting out a non-penetrating cutout 1031 at the installation site and drilling a drainage aperture 1136 through a bottom 1035 of the non-penetrating cutout 1031.

Here has thus been described a multitude of embodiments of the adaptable shower pan system 100, 400, 600, 800, and methods related thereto, which can be employed in numerous modes of usage.

The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention, which fall within the true spirit and scope of the invention.

Many such alternative configurations are readily apparent, and should be considered fully included in this specification and the claims appended hereto. Accordingly, since numerous modifications and variations will readily occur to those skilled in the art, the invention is not limited to the exact construction and operation illustrated and described, and thus, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

1. An adaptable shower pan system, comprising:

a) a floor plate with a convex upper surface, such that the convex upper surface comprises a highest point within a central portion of the convex upper surface; and
b) a bottom pan, comprising: a bottom structure further comprising a drainage center and a drainage aperture, such that the bottom structure is configured to rest on a floor structure, wherein the bottom structure is configured with a structure surface that slopes toward the drainage center; and a plate support structure, which is positioned on the structure surface of the bottom structure, such that the plate support structure comprises a plurality of flat upper contact surfaces, such that the floor plate is configured to rest stably on the plate support structure, such that the plate support structure is configured to allow water to drain from outer sides of the structure surface to the drainage center;
wherein the floor plate is smaller than the bottom pan, such that a drainage gap is formed on all sides of the floor plate;
such that the water drains from the convex upper surface of the floor plate, via the drainage gap, and the drainage center, to the drainage aperture.

2. The adaptable shower pan system of claim 1, further comprising a side structure, such that the side structure is connected around rear and side edges of the bottom pan to form a watertight assembly, wherein the side structure comprises:

a) a left side member;
b) a rear side member, such that a left end of the rear side member is perpendicularly connected to a rear end of the left side member; and
c) a right side member, such that a rear end of the right side member is perpendicularly connected to a right end of the rear side member.

3. The adaptable shower pan system of claim 2, further comprising:

a front structure, which is connected to a front side of the bottom pan;
such that the side and front structures are connected around an outer edge of the bottom pan to form a watertight assembly.

4. The adaptable shower pan system of claim 2, wherein:

a) the left side member comprises: a first horizontal elongated piece; and a first vertical elongated piece, which is perpendicularly connected to the first horizontal elongated piece, along a left edge of the first horizontal elongated piece;
b) the right side member comprises: a second horizontal elongated piece; and a second vertical elongated piece, which is perpendicularly connected to the second horizontal elongated piece, along a right edge of the second horizontal elongated piece; and
c) the rear side member comprises: a third horizontal elongated piece; a third vertical elongated piece, which is perpendicularly connected to the third horizontal elongated piece, along a rear edge of the third horizontal elongated piece.

5. The adaptable shower pan system of claim 4, wherein:

a) the left side member further comprises: a first rectangular end piece, which is connected to first rear ends of the first horizontal and first vertical elongated pieces; and
b) the right side member further comprises: a second rectangular end piece, which is connected to second rear ends of the second horizontal and second vertical elongated pieces.

6. The adaptable shower pan system of claim 5, wherein:

a) the left side member is a first one sheet piece, such that the first horizontal elongated piece comprises a first lateral cut and the first vertical elongated piece comprises a first lateral fold that is connected to the first lateral cut, such that a first rear end of the first vertical elongated piece is folded around the lateral fold, such that a rear flap of the first horizontal elongated piece is folded onto the first horizontal elongated piece, such that the rear end of the first vertical elongated piece forms the first rectangular end piece; and
b) the right side member is a second one sheet piece, such that the second horizontal elongated piece comprises a second lateral cut and the second vertical elongated piece comprises a second lateral fold that is connected to the second lateral cut, such that a second rear end of the second vertical elongated piece is folded around the second lateral fold, such that a second rear flap of the second horizontal elongated piece is folded onto the second horizontal elongated piece, such that the second rear end of the second vertical elongated piece forms the second rectangular end piece.

7. The adaptable shower pan system of claim 1, wherein the support structure further comprises a plurality of support ribs, such that a height of each support rib increases from an outer end to an inner end, such that upper surfaces of the support ribs are flat and form a flat plane on which the floor plate is configured to be stably positioned.

8. The adaptable shower pan system of claim 7, wherein each support rib in the plurality of support ribs is configured to point in a direction toward the drainage center of the bottom structure.

9. The adaptable shower pan system of claim 1, further comprising a side structure, which is connected to wall sides of the bottom pan, such that the side structure is connected around rear and side edges of the bottom pan to form a watertight assembly, wherein the side structure comprises:

a) a first side member; and
b) a second side member;
wherein the first and second side members are perpendicularly connected;
such that the adaptable shower pan system is configured for corner installation.

10. The adaptable shower pan system of claim 7, wherein the bottom pan further comprises a plurality of support connectors, which are attached to top sides of the support ribs, such that each support connector provides a flat support area for the floor plate, such that each support connector comprises:

a) a top support plate with a top surface that is configured to be the flat support area;
b) a first connector flange that is perpendicularly connected along a bottom of the top support plate; and
c) a second connector flange that is perpendicularly connected along a bottom of the top support plate;
wherein the first and second connector flanges are parallel and mounted side by side with an opening between the first and second connector flanges, such that the support connector is configured to slide firmly onto a support rib, with a part of a support rib inside the opening.

11. The adaptable shower pan system of claim 10, wherein the support connectors are permanently adhered to a bottom of the floor plate with a predetermined position of the support connectors, such that the floor plate is removably positionable on the support ribs in a fixed position, such that there is a uniform drainage gap on all sides of the floor plate.

12. The adaptable shower pan system of claim 1, wherein the bottom structure further comprises a flat central area, which is configured to allow a customized location of the drainage aperture, such that the drainage aperture is cut in the flat central area to match a specific location of a drain in the floor structure, whereby the adaptable shower pan system is configured to be adaptable to varying locations of the drain in the floor structure.

13. The adaptable shower pan system of claim 1, wherein the convex upper surface is configured as a segment of a sphere.

14. The adaptable shower pan system of claim 1, wherein the bottom structure further comprises:

an elongated drainage canal, which extends from the drainage center of the bottom structure to the drainage aperture;
such that water flows from all sides of the floor plate, down the structure surface of the bottom structure to the drainage center, and via the drainage canal to the drainage aperture.

15. The adaptable shower pan system of claim 14, wherein the bottom structure further comprises:

a sealing plate;
wherein the elongated drainage canal is configured as a penetrating cutout, which penetrates through the bottom structure;
such that an initial portion of the penetrating cutout is closed with the sealing plate, which is glued to a bottom side of the bottom structure, such that the initial portion is sealed, such that a final portion of the penetrating cutout remains open to form the drainage aperture.

16. The adaptable shower pan system of claim 14, wherein the elongated drainage canal is configured as an elongated indentation of the structure surface of the bottom structure, wherein a bottom of the elongated indentation comprises the drainage aperture.

17. An adaptable shower pan system, comprising:

a) a floor plate; and
b) a bottom pan, comprising: a bottom structure, further comprising an elongated drainage canal, which extends from a drainage center of the bottom structure to a drainage aperture; and a plate support structure, which is positioned on a structure surface of the bottom structure, such that the plate support structure comprises a plurality of flat upper contact surfaces, such that the floor plate is configured to rest stably on the plate support structure, such that the plate support structure is configured to allow water to drain from outer sides of the structure surface to the drainage center;
wherein the floor plate is smaller than the bottom pan, such that a drainage gap is formed on all sides of the floor plate;
such that the water drains from an upper surface of the floor plate, via the drainage gap, down the structure surface to the drainage center, and via the drainage canal to the drainage aperture.

18. The adaptable shower pan system of claim 17, wherein the upper surface is convex, such that the upper surface comprises a highest point within a central portion of the upper surface.

19. The adaptable shower pan system of claim 17, wherein the bottom structure further comprises:

a sealing plate;
wherein the elongated drainage canal is configured as a penetrating cutout, which penetrates through the bottom structure;
such that an initial portion of the penetrating cutout is closed with the sealing plate, which is glued to a bottom side of the bottom structure, such that the initial portion is sealed, such that a final portion of the penetrating cutout remains open to form the drainage aperture.

20. The adaptable shower pan system of claim 17, wherein the elongated drainage canal is configured as an elongated indentation of the structure surface of the bottom structure, wherein a bottom of the elongated indentation comprises the drainage aperture.

21. The adaptable shower pan system of claim 17, further comprising:

a front structure, which is connected to a front side of the bottom pan; and
a side structure, which is connected to wall sides of the bottom pan to form a watertight assembly.
Patent History
Publication number: 20190191932
Type: Application
Filed: Dec 2, 2018
Publication Date: Jun 27, 2019
Inventor: Thomas Joseph Costello (Covina, CA)
Application Number: 16/207,153
Classifications
International Classification: A47K 3/40 (20060101);