US20180184854A1

US20180184854A1 - Modular shower pan

Info

Publication number: US20180184854A1
Application number: US15/858,189
Authority: US
Inventors: Paul Salvatore
Original assignee: Paul Salvatore
Current assignee: Bolger Daniel
Priority date: 2017-01-03
Filing date: 2017-12-29
Publication date: 2018-07-05

Abstract

A modular shower pan is formed as a body having a floor with a drain hole and a support surface formed from raised portions extending upward from the floor and defining a level plane above the floor and over the drain hole, that is configured to support a slab shower floor thereon concealing the drain hole. The upper surfaces of the raised portions and the slab positioned thereon pitch downward toward a rear of the pan. Perimeter drainage passages along a perimeter of the shower pan are connected to drainage channels that pitch downward to the drain hole. The slab is dimensioned to cover the drain hole but to allow water to flow over its edges into the perimeter passages. In use, water falling onto the slab flows preferentially rearward on the pitched slab, spilling over the edges, into perimeter drainage passages and down the channels to the drain hole.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application Ser. No. 62/441,736, entitled MODULAR SHOWER PAN, filed Jan. 3, 2017, the entirety of which is hereby incorporated herein by reference thereto.

FIELD OF DISCLOSURE

The present disclosure relates generally to bathroom shower constructions, in particular, to a modular shower pan.

BACKGROUND

Shower pans or bases are typically constructed with either a pre-molded solid fiberglass or acrylic base, or are built in a layered construction with an upper tiled surface. In either type of construction, the base typically includes an aperture for the drain. A grating is provided over the drain which may be easily clogged, is uncomfortable to stand on with bare feet, and detracts from an otherwise appealing tiled surface construction.
As illustrated in FIG. 1, the conventional type of shower base constructed with an upper tiled surface, requires, among other things, preparation of a mortar bed with an upper sloping surface 2 forming the base, constructed on a plywood subfloor 4. A water-resistant shower liner is then laid on the upper surface 2 of the mortar bed, and extends upward behind vertical cement board 6 that is installed against the vertical walls forming the shower enclosure. It is not unusual for a gap to remain between the cement board 6 and the shower liner, resulting in a leaky pan. Lastly, the shower tiles 8 must be cut as needed and installed to be level with the upper surface of the shower drain 9. These conventional mud pans have several disadvantages in addition to the leaky pan liners. These include costly labor-intensive installation, retention of moisture and standing water, unsightly exposed drains, loose tile issues, broken grout, and high maintenance.
Because of these disadvantages, pre-molded shower pans, requiring no tiling, have become more common. Pre-molded solid fiberglass or acrylic types are typically designed to be installed on a flat subfloor and are provided with a sloped top surface so that water flows toward the drain. These types of bases, while easier to install than the tiled variety, are not as durable or as aesthetically pleasing as tile or other surfaces, such as stone.
Some attempts have been made in the prior art to at least address the problem of the exposed drains in tiled shower constructions. For example, U.S. Pat. No. 8,918,926 to Herring discloses a one-piece pre-molded shower drain pan onto which is installed an upper tiled shower floor. The drain pan is encapsulated in a water proof membrane, and has a recessed portion coinciding with the drain. An insert is positioned over the recessed drain which has the appearance of the surrounding tiles. A perimeter water flow space is maintained between the edges of the insert and the surrounding tile surface.
None of the prior art, including Herring, offer a modular shower pan design that accommodates any pre-cut solid slab, requiring no tiling, for covering the entire shower pan, including the drain.
There is a need, therefore, for a modular shower pan that allows any solid slab floor to be easily installed over the shower pan, including over the drain.

SUMMARY

Features of the disclosure will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of this disclosure.
The present disclosure is directed to a modular shower pan that allows any suitably dimensioned solid slab floor to be easily installed over the shower pan, covering and concealing the drain.
The present disclosure is also directed to a modular shower pan including a body having a floor with a drain hole therethrough and a support surface formed from raised portions extending upward from the floor. The support surface defines a level plane above the floor that extends from a front side to a rear side of the floor and over the drain hole, and that is configured to support a slab thereon to form a shower floor that covers and conceals the drain hole.
In aspects, the support surface is pitched downward from the front side toward the rear side of the floor.
In other aspects, the raised portions include perimeter rails aligned parallel to and extending along at least a portion of a perimeter of the floor including along at least a portion of the rear side of the floor.
The raised portions may further include raised pads positioned between the perimeter rails and the drain hole.
In some aspects, the support surface formed from an upper surface of the raised portions is pitched downward from the front side toward the rear side of the floor.
In additional aspects, the body further includes an inner perimeter wall surrounding the floor, and perimeter drain passages formed between the inner perimeter wall and the perimeter rails.
The modular shower pan may further include, in aspects, a plurality of drainage channels in the floor, each of the plurality of drainage channels connecting one of the perimeter drain passages to the drain hole, wherein each of the drainage channels is pitched downward toward the drain hole.
Regions of the floor extending interior to the perimeter rails and outside of the drainage channels is also preferably pitched downward along a radial path to the drain hole.
In one aspect, a pitch of the drainage channels and of the floor outside of the drainage channels to the drain hole is about ¼ inch to about ½ inch per foot.
Each of the drainage channels may be formed between a pair of channel rails, wherein a portion of the support surface is formed from upper surfaces of the channel rails.
In yet another aspect, the pitch of the support surface from the front side to the rear side is between about ⅛ inch to about ¼ inch per foot.
In still additional aspects, the body further includes a raised curb that borders the front side of the floor and is configured to form an entrance threshold of the shower enclosure upon installation, the raised curb also forming a portion of the inner perimeter wall surrounding the floor.
In another aspect, the body of the modular shower pan is formed of fiberglass.
The present disclosure is also directed to a shower floor assembly for a shower enclosure, the assembly including a slab configured to form a shower floor, and a modular shower pan configured to install in a shower enclosure. The modular shower pan includes a body having a floor with a drain hole therethrough and a support surface formed from raised portions extending upward from the floor, the support surface defining a level plane above the floor that extends from a front side to a rear side of the floor and over the drain hole, and that is configured to support the slab thereon. The slab is configured to cover and conceal the drain hole upon installation on the support surface of the modular shower pan.
In aspects, the raised portions include perimeter rails aligned parallel to and extending peripherally along at least a portion of each side of the floor. The body further includes an inner perimeter wall surrounding the floor, and perimeter drain passages formed between the inner perimeter wall and the perimeter rails. In additional aspects, the support surface is formed at least in part by the perimeter rails. The slab is configured to extend onto the perimeter rails and to leave at least a portion of each of the perimeter drain passages uncovered when installed, thereby allowing water falling onto the slab to spill over its edges and into the perimeter drain passages.
In aspects, the modular shower pan further includes a plurality of drainage channels in the floor, each of the plurality of drainage channels connecting one of the perimeter drain passages to the drain hole. Each of the drainage channels is pitched downward toward the drain hole.
In aspects, each of the drainage channels is formed between a pair of channel rails, the raised portions including the channel rails, a portion of the support surface being formed from upper surfaces of the channel rails.
In some aspects, the support surface formed from an upper surface of the raised portions is pitched downward from the front side toward the rear side of the floor.
In other aspects, the support surface formed from an upper surface of the raised portions is leveled to a horizontal plane, and an upper surface of the slab is pitched downward from the front side toward the rear side of the floor.
The raised portions may further include raised pads positioned between the perimeter rails and the drain hole.
In aspects, the slab is at least ¾ inch thick.
The slab may be glued onto the support surface upon installation on the modular shower pan.
In additional aspects, the slab is made of stone.
In other aspects, the slab is made of a man-made material.
The present disclosure is also directed to a modular shower pan that includes raised portions positioned on a floor of the shower pan. The raised portions may have upper surfaces pitched downward toward a rear of the shower pan. The shower pan includes a pitched support surface formed from the upper surfaces. The pitched support surface is constructed to form a level support surface for supporting a solid slab shower floor upon installation. The modular shower pan also includes perimeter drain passages along at least a rear portion of the shower pan. The modular shower pan includes a drain hole and drainage channels connecting the perimeter drain passages to the drain hole via the drainage channels, wherein the drainage channels are pitched downward toward the drain hole.
Upon installation, and in use, water falls onto the solid slab positioned on the preferably pitched support surface. The solid slab is dimensioned to cover the drain hole but to allow water to flow over its edges and into the perimeter drain passages. The water flows toward the rear of the shower pan, as well as along the sides, into perimeter drain passages, and into the channels connected thereto, and follows the downward pitch to the drain hole.
In aspects, the raised portions include rails that form a side of the perimeter drain passages.
In additional aspects, the raised portions also include raised pads positioned between the perimeter drain passages and the drain hole.
In additional aspects, the modular shower pan is an integral unitary pre-molded structure.
In addition to the above aspects of the present disclosure, additional aspects, objects, features and advantages will be apparent from the embodiments presented in the following description and in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this disclosure and include examples, which may be implemented in various forms. It is to be understood that in some instances, various aspects of the disclosure may be shown exaggerated or enlarged in the drawings to facilitate understanding, so that the different features are not necessarily represented in the exact proportion to each other to which they would be manufactured. The teaching of the disclosure can be readily understood by considering the detailed description in conjunction with the accompanying drawings, which are briefly described below.

FIG. 1 is a representation of a conventional layered installation of a tiled shower floor.

FIG. 2A is a perspective view of an embodiment of a modular shower pan of the present disclosure.

FIG. 2B is a cross-sectional view from front to rear (left to right, respectively, in FIG. 2B) through the center of the drain hole of the modular shower pan of FIG. 2A.

FIG. 2C is a magnified view of the area around the drain hole of the shower pan of FIG. 2A.

FIG. 2D is a cross-sectional view from front to rear (left to right, respectively, in FIG. 2D) of the modular shower pan of FIG. 2A, with a solid slab floor positioned thereon, traversing a pair of support pads and perpendicular to rails.

FIG. 2E is a cross-sectional view from side to side of the modular shower pan of FIG. 2A, with a solid slab floor positioned thereon, traversing a pair of support pads and perpendicular to rails.

FIG. 2F is a cross-sectional view from front to rear (left to right, respectively, in FIG. 2F) of another embodiment of the modular shower pan of the disclosure, with a solid slab floor having a wedged profile positioned thereon.

FIG. 3 depicts the direction of water flow along the channels and along the downward pitch of the floor and drainage channels and into the drain hole of the modular pan of FIG. 2A.

FIG. 4 is another embodiment of a modular shower pan of the present disclosure.

FIG. 5 is a shower enclosure with the modular pan of FIG. 2A installed therein.

FIG. 6 is the shower enclosure with modular pan of FIG. 5 with a solid slab floor installed in accordance with the disclosure.

The various aspects of the present disclosure mentioned above are described in further detail with reference to the aforementioned figures and the following detailed description of exemplary embodiments.

DETAILED DESCRIPTION

Particular illustrative embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, the disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms. It should be apparent to those skilled in the art that the described embodiments provided herein are illustrative only and not limiting, having been presented by way of example only. All features disclosed in this description may be replaced by alternative features serving the same or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the modifications thereof are contemplated as falling within the scope of the present disclosure of a modular shower pan as defined herein and equivalents thereto. Well-known functions or constructions and repetitive matter are not described in detail to avoid obscuring the present disclosure in unnecessary or redundant detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting. In this description, as well as in the drawings, like-referenced numbers represent elements which may perform the same, similar, or equivalent functions.
Throughout the description, where items are described as having, including, or comprising one or more specific components or features, or where methods are described as having, including, or comprising one or more specific steps, it is contemplated that, additionally, there are items of the present disclosure that consist essentially of, or consist of, the one or more recited components or features, and that there are methods according to the present disclosure that consist essentially of, or consist of, the one or more recited processing steps.
The present disclosure is directed to a modular shower pan that allows any solid slab to be easily installed over the shower pan, including over the drain. The modular shower pan is preferably of unitary construction, so that it is ready to install in one piece. The modular shower pan of the present disclosure may be formed of any appropriate material. In embodiments, the modular shower pan is formed as a body of unitary molded fiberglass.
As shown in an embodiment 10 of the modular shower pan represented in FIG. 2A, the shower pan 10 is a body of unitary, preferably molded, construction. The modular shower pan includes a drain hole 12 positioned to coincide with the opening to a drain pipe. It is understood by those of skill in the art that while the drain hole 12 shown in FIG. 2A is centrally located, and the shower pan 10 is rectangular in shape, the present disclosure encompasses and contemplates any number of variations in the shape of the shower pan, and any variation in the placement of the drain hole 12 to properly coincide with the position of the drain pipe over which it is to be installed.
Referring to FIGS. 2A-E, and FIG. 3, for facilitating flow (as shown by flow lines 11 in FIG. 3) of water that falls onto the floor 44 of the modular shower pan from the shower floor (upper surface of solid slab 21 in the figures), the modular shower pan 10 includes perimeter drain passages 14 along each of the four sides of the modular shower pan 10. A plurality of channels 16 connect the perimeter drain passages 14 to the drain hole 12. The channels 16 are pitched downward toward the drain hole 12, so that the water collected by the perimeter drain passages 14 flows into the pitched channels 16 and towards the drain hole 12. Once entering via the drain hole 12, the water flows through a waste line and trap assembly 22 as shown.
As shown, for example, in FIG. 2B, the pitch 19 of each channel 16 is, in embodiments, about ¼ inch to about ½ inch per foot. In particular embodiments, the pitch is about ¼ inch per foot, or ¼ inch+/−about 1/32-inch tolerance. Each channel may have about the same pitch. In some embodiments, different channels, or pairs of channels (front to back versus side to side), may have slightly different pitches from one another.
As shown in FIG. 2A, as well as in FIG. 3, while the drainage channels 16 are pitched downward toward the drain, the remainder of the floor 44 of the modular pan in the regions 38 bounded by the perimeter 20 and channel rails 18 is also pitched downward radially toward the drain, with the diagonal cross-sections through the drain also having a pitch, in embodiments, on the order of about ¼ inch per foot. This facilitates the flow of water that spills over onto any part of the floor 44 of the pan 10 to have a downward path to the drain 12. As one of skill in the art will appreciate, in cross-sectional views from front 54 to rear 46 of the modular pan 10, as shown, e.g., in FIG. 2D, the angular deviation 45 of the floor tilting along that cross-section will not be as large as it is along a radial cross-section, will be even less evident in the side-to-side cross-section of FIG. 2E, and in the transverse cross-sections of FIGS. 2E and 2D, will also depend upon the distance of the cross-sectional view from the drain 12.
In embodiments, any one or more of the perimeter drain passages 14, for example, a rearmost drain passage as shown in FIG. 2A, may be covered by a stainless-steel strainer 13 that is substantially parallel to the top surface of the drain passage 14.
Alternatively, in other embodiments, a stainless-steel strainer 15 may be provided, perpendicular to the water flow (and to the floor) at each entrance point of water flow from the perimeter drain passages 14 to each of the pitched channels 16.
As also shown in FIGS. 2C-2E, the channels 16 are preferably formed between rails 18 that protrude or extend upward from the floor of the shower pan 10. The modular shower pan 10 also preferably includes perimeter rails 20 to form an inner side of the perimeter drain passages 14. Each perimeter rail 20 is preferably connected to at least one of the channel rails 18 to form a path between the perimeter drain passages 14 and the channels 16, as shown in FIGS. 2A and 3. Each perimeter rail 20 that is aligned along a side of the modular shower pan may also be integral with and perpendicular to an adjacent perimeter rail 20 aligned along one of a front and a rear of the modular shower pan. This arrangement forms a continuous pathway for water that falls from the edges of the slab 21 into any portion of the perimeter passages 14 to then flow from the perimeter passages 14 into the channels 16 and downward to the drain hole 12. In the embodiment shown in FIGS. 2C-2E, each of two adjacent and connected perpendicular perimeter rails 20 are connected to a channel rail 18 as shown to form one unitary raised surface in the shape of a rectangle. Referring to FIGS. 2D and 2E, both channel rails 18 and perimeter rails 20, in embodiments, are constructed of sufficient height to provide at least part of a support surface 25 on which a solid slab 21 will be installed over the modular pan 10.
Strainers 13 for covering each of the drain passages 14 may be provided as part of a kit for installing the modular pan 10. Each strainer 13, upon installation with a slab shower floor 21, is configured to cover the gap between the edge of the slab 13 and the shower enclosure to filter out debris, hair, and so on from shower water before it flows into the drain passages 14.
Preferably, an outer side of the perimeter drain passages 14 is provided by an inner perimeter wall 23 surrounding the floor 44 of the modular shower pan 10. In embodiments, the inner perimeter wall 23 is configured to allow bonding of tiles or other surfaces to it upon installation of the modular shower pan 10 with a surrounding shower enclosure, as further described below. Inner wall 23 also retains water spilling onto the floor 44 within the pan and forms an outer side, parallel to rails 20, of the perimeter drains passages 14.
Referring particularly to FIG. 2E, to facilitate secure mounting of a shower enclosure around the shower pan 10 upon installation and to assist in proper watershed, the modular shower pan 10 preferably includes, e.g., a ½ inch deep raised step 24 along each of three sides in the embodiment shown (generally, along each side except for the entrance/door side) for accommodating ½ inch thick wall board/tile backer 26 or other types of enclosure walls. Upon assembly of each tile backer 26 onto one of the steps 24 and securing it to a wall structure 28, for example, tiles are installed onto the tile backer 26 according to methods well known in the art to form a vertical tiled enclosing wall 30. In embodiments, the tiles may be installed onto the tile backer 26 as well as over at least a portion of the inner walls 23, the surface of which is flush with the installed ½ inch thick tile backer 26 by virtue of the ½ inch deep raised step 24. To accommodate tile backers or a layered construction having a thickness other than ½ inch, other embodiments of the modular shower pan may include a raised step 24 of appropriate thickness.
The fourth side of the modular shower pan 10 shown in the embodiment of FIG. 2A includes a raised threshold curb 32 that borders a front side of the shower pan 10, forming the bottom edge of a shower enclosure through which a user enters the shower. An interior facing wall of the raised threshold curb 32 also preferably forms the front one of the inner perimeter walls 23. The raised threshold curb 32 is preferably configured to allow bonding of a side of the solid slab 21 to it, as well as to allow bonding of tile or other additional decorative surfaces to its top and outer sides, if desired.
Referring, e.g., to FIGS. 2A and 2C-2E, in embodiments, the modular shower pan 10 also includes raised support pads 42 positioned on the floor 44 of the modular pan 10, which together with rails 20, support the solid slab 21 once installed. Support pads 42, and side support rails 20, in embodiments, are pitched with a slight decline toward the rear 46 of the shower pan 10 to assist in watershed and prevent puddling. Support rails 20, together with support pads 42, form a level, i.e., flat, planar support surface 25 on which the solid surface 21 is positioned. Accordingly, referring to FIG. 2D, which shows a solid slab 21 positioned on the support surface 25 formed by the raised support pads 42 and rails 18, 20, an upper surface 50 of the solid slab 21, once installed, is preferably set at an angle 47 which is pitched so that most of the water flows into the perimeter drainage passage 14 at the rear 46 of the pan 10, and also into rear portions of two adjacent perimeter drain passages 14 formed between the inner perimeter wall 23 (which may be tiled) and the corresponding rails 20. Unlike prior art shower pans, no water flows directly from the upper surface of the shower floor, in this case, the upper surface of solid slab 21, directly into the drain.
A “level” surface refers herein to a surface that is levelled to a plane, which may, or may not be the horizontal plane, as further described herein.
In embodiments, the support surface 25 provides a downward pitch 47 of the upper surface of the slab 21 toward the rear 46 of the shower pan, which is preferably about ⅛-inch per foot. In other embodiments, the pitch 47 may be between about ⅛ to about ¼-inch per foot. In the embodiments shown, it is assumed that the solid slab 21 is of uniform thickness, and the support surface 25 formed from the upper surfaces of the rails 18, 20 and support pads 42 is pitched at the desired angle, downward toward the rear 46 of the shower pan. In other embodiments, the support surface 25 may be configured to be level to the horizontal plane, as installed. The pitch 47, in this embodiment, for facilitating water flow from the upper surface of the slab 21 into the rearward perimeter drain passages may then be obtained by pitching the upper surface of the slab relative to the support surfaces 25, i.e., using a slab that has a gradient thickness that decreases from front to the rear of the slab 21 to form a downward pitch 47 toward the rear 46 as installed onto the shower pan 10.
The level, planar support surface 25 provided by the rails and pads, while tilted toward the rear 46 of the pan 10, is level to the horizontal plane along the direction extending from one side to the other, transverse to the front to rear direction of the pan, as shown in the cross-sectional side-side view of FIG. 2E.
As one of skill in the art will appreciate, the various pitches for achieving desired water flow in the modular pans are configured relative to predetermined plane surfaces of the modular pan, which are made level to the horizontal plane upon installation. Though it is contemplated that other surfaces may be used, in preferred embodiments shown, the planar horizontal surfaces of the steps 24, along with the horizontal surface 48 of the raised threshold curb 32 may be configured to be flat, planar surfaces that are parallel to one another, and can be easily levelled to the horizontal plane upon installation of the pan. This horizontally levelled plane is the reference plane for the angles of the various pitched surfaces.
The support pads 42, along with the rails 20 and other features of the modular shower pan 10 preferably form one integral unitary structure on which the solid slab 21 is installed. Any suitable means of installation may be employed to properly position the solid slab 21 in place on the modular shower pan 10. As shown in 2E, for example, the solid slab 21 is sized to extend over the support rails 20, while leaving a sufficient portion of the perimeter passages 14, which preferably form about a ¼-inch to ⅜-inch perimeter border along each of the four sides of the modular shower pan 10, uncovered for proper drainage. Once installed with the solid slab 21, the modular pan 10 provides a clean, comfortable, and continuous shower floor, that is also aesthetically pleasing, concealing the drain hole and other water passages beneath the finished solid slab 21.
In embodiments, a top surface of each of the support pads 42 may be pre-coated with any appropriate adhesive covered by a peal-away type cover, the cover being removed upon installation of the solid slab 21. In this way, the lower surface of the solid slab 21 may be adhered to the support pads 42. In other embodiments, a suitable adhesive may be applied to the support pads at the time of installation.
As described supra, although the embodiments show that the solid slab 21 is a flat level slab of uniform thickness, one could also presumably use a solid slab that has a top surface with a preconfigured pitch relative to its lower surface. In this case, as shown in FIG. 2F, the support surface 25 provided by the rails 20 and pads 42 may be configured to be level to a horizontal plane 51 when installed, and the pitch 47 for water flow from a front 54 to the rear of the modular pan 10 may then be provided by a properly pitched and installed solid slab 52 having an appropriate thickness gradient, i.e., having a wedged profile as shown. As one of skill in the art will appreciate, however, providing the solid surface 21 with such a preconfigured pitch may limit the types of solid surfaces that can be used.
One of skill in the art will also appreciate that embodiments of the modular shower pan 10 of the present disclosure having the drainage and modular features, as well as the aesthetic features described herein, may be adapted to be installed with different shower enclosures than the embodiment shown. For example, the shower enclosure may include (but is not limited to) two tiled shower walls, and two clear walls, at least one of which forms the door, or two tiled shower walls and only one curved door structure between the two tiled shower walls. In the latter example, an embodiment of the modular shower pan 10 may be shaped with two perpendicular sides and a third curved side to accommodate a curved door.
One of skill in the art will also appreciate that the various elements of the modular shower pan of the present disclosure may encompass any suitable configuration and shape to provide the utility of the features described herein. For example, referring to an embodiment 55 of a modular shower pan shown in FIG. 4, any suitable number and shape of raised pads 56 may be provided, which may be appropriately pitched to provide water flow from an installed solid slab toward the rear of the pan. As shown in the figures, the pads 56 may be polygonal, e.g., rectangular, triangular, and so on; elliptical, e.g., circular; or any other shape and size providing a sufficient amount of surface area for supporting a slab shower floor. In addition, channels 16 may be positioned to connect the perimeter passages 14 at the sides of the modular shower pan 10 as shown in FIG. 2A, at the corners as provided in FIG. 4, or any suitable combination, as long as they are appropriately pitched downward toward the drain hole 12.
Embodiments of the shower pan of the present disclosure are shown herein to be configured for installation in a conventional rectangular-type shower enclosure. The standard dimensions of such enclosures may be, e.g., about 36 inches in width for the two opposing sides, and in embodiments, the front and rear sides may be of a length between 36 and 72 inches, e.g., 36 inches, 48 inches, 60 inches, and 72 inches are some of the more common standardized lengths. One of skill in the art will appreciate that embodiments of the modular shower pan of the present disclosure may also be configured for installation of three-sided, five-sided, or any other shaped shower enclosure.
The term “slab” as used herein is understood to refer to a solid, unitary, piece of material with no cutouts for a drain hole, preferably having at least one substantially flat, planar surface for mounting on the modular shower pan, and preferably having a thickness of at least ¼″, preferably at least ½″.
In embodiments, the slab has a thickness of at least ⅝″. In other embodiments, the thickness of the slab has a thickness of at least ¾ inch. In still other embodiments, the slab may range from about ¾″ to about 1″. In still other embodiments, the thickness of the slab may range from about ¾″ to about 1½″.
As described further herein, in embodiments, the slab floors of the present invention may be of uniform thickness across the entire slab. In other embodiments, the thickness of the slab may be pitched along the direction installed from front to rear of the shower pan. The modular shower pan of the present disclosure is constructed to support a wide variety of solid unitary structures or slabs, which may be precut and ready to drop as one piece onto the modular shower pan. Any appropriate natural or man-made material may be used.
In one embodiment, the solid slab may be formed of stone. In another embodiment, a preconfigured manmade slab having a decorative surface, formed of sufficient supportive thickness, may be laid onto the support surface of the modular shower pan. The slabs may also be glued to the support surface.
The present disclosure provides a modular shower pan configured to install a single, solid slab thereupon. The modular pan 10 represented in the figures is configured as a body with a floor 44 configured with a pitch to direct water falling thereon downward to the drain hole 12, and raised portions extending upward from the floor 44, rails 18, 20 and support pads 42, that provide a support surface 25 defining a level plane configured to support a solid slab shower floor 21 that covers the floor 44 and drain hole 12. The support surface 25, in embodiments, is pitched so that the upper surface of a slab 21 positioned thereon is pitched toward the rear of a shower enclosure 60, as shown in FIG. 5, i.e., toward the rear 46 of the modular pan 10. The solid slab 21 is configured for installation on the support surface 25 such that a gap is left between the edges 62 of the slab 21 and the enclosure walls, as shown in FIG. 6. As shown in 2E, the solid slab 21 is sized to extend over the support rails 20, while leaving a sufficient portion of the perimeter passages 14 uncovered for proper drainage Accordingly, water falling onto the slab 21 in use flows over the edges 64 of the slab 21 and into the perimeter channels 14. In embodiments, the flow pattern 62 on the surface of the slab 21 preferentially provides water flow toward the rear 46 by providing a downward pitch as described herein. Once water flow over the edges of the slab 21 and into the perimeter channels 14, as shown in FIG. 3, e.g., it is directed along the channels 14, into the downward pitched drain channels 16 and into the drain 12. Because of the radially directed pitch of the floor 44 of pan 10, any water that may flow over the perimeter rails 20 or channel rails 18, is also directed toward the drain 12.
While particular embodiments of the present disclosure have been particularly shown and described with reference to specific embodiments, it should be apparent to those skilled in the art that the foregoing is illustrative only and not limiting, having been presented by way of example only. It is to be understood that the disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms and detail without departing from the spirit and scope of the disclosure. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting. Numerous other embodiments may fall within the scope of the accompanying claims and equivalents thereto.

Claims

What is claimed is:

1. A modular shower pan, the modular shower pan comprising:

a body having a floor with a drain hole therethrough and a support surface formed from raised portions extending upward from the floor, the support surface defining a level plane above the floor that extends from a front side to a rear side of the floor and over the drain hole, and that is configured to support a slab thereon to form a shower floor.

2. The modular shower pan of claim 1, wherein the support surface is pitched downward from the front side toward the rear side of the floor.

3. The modular shower pan of claim 1, wherein the raised portions include perimeter rails aligned parallel to and extending along at least a portion of a perimeter of the floor including along at least a portion of the rear side of the floor.

4. The modular shower pan of claim 3, wherein the raised portions further include raised pads positioned between the perimeter rails and the drain hole.

5. The modular shower pan of claim 4, wherein the support surface formed from an upper surface of the raised portions is pitched downward from the front side toward the rear side of the floor.

6. The modular shower pan of claim 3, wherein the body further comprises an inner perimeter wall surrounding the floor, and perimeter drain passages formed between the inner perimeter wall and the perimeter rails.

7. The modular shower pan of claim 6, further comprising a plurality of drainage channels in the floor, each of the plurality of drainage channels connecting one of the perimeter drain passages to the drain hole, wherein each of the drainage channels is pitched downward toward the drain hole.

8. The modular shower pan of claim 7, wherein the floor extending interior to the perimeter rails and outside of the drainage channels is also pitched downward along a radial path to the drain hole.

9. The modular shower pan of claim 8, wherein a pitch of the drainage channels and of the floor outside of the drainage channels to the drain hole is about ¼ inch to about ½ inch per foot.

10. The modular shower pan of claim 7, wherein each of the drainage channels is formed between a pair of channel rails, the raised portions including the channel rails, a portion of the support surface being formed from upper surfaces of the channel rails.

11. The modular shower pain of claim 2, wherein the pitch of the support surface from the front side to the rear side is between about ⅛ inch to about ¼ inch per foot.

12. The modular shower pan of claim 6, the body further comprising a raised curb that borders the front side of the floor and is configured to form an entrance threshold of the shower enclosure upon installation, the raised curb also forming a portion of the inner perimeter wall surrounding the floor.

13. A shower floor assembly for a shower enclosure, the assembly comprising:

a slab configured to form a shower floor; and

a modular shower pan configured to install in a shower enclosure, the modular shower pan comprising a body having a floor with a drain hole therethrough and a support surface formed from raised portions extending upward from the floor, the support surface defining a level plane above the floor that extends from a front side to a rear side of the floor and over the drain hole, and that is configured to support the slab thereon, the slab configured to cover and conceal the drain hole upon installation on the support surface of the modular shower pan.

14. The assembly of claim 13, wherein the raised portions include perimeter rails aligned parallel to and extending peripherally along at least a portion of each side of the floor, the body further comprising an inner perimeter wall surrounding the floor and perimeter drain passages formed between the inner perimeter wall and the perimeter rails, the support surface being formed at least in part by the perimeter rails, and wherein the slab is configured to extend onto the perimeter rails and to leave at least a portion of each of the perimeter drain passages uncovered when installed, thereby allowing water falling onto the slab to spill over its edges and into the perimeter drain passages.

15. The assembly of claim 14, the modular shower pan further comprising a plurality of drainage channels in the floor, each of the plurality of drainage channels connecting one of the perimeter drain passages to the drain hole, wherein each of the drainage channels is pitched downward toward the drain hole.

16. The assembly of claim 15, wherein each of the drainage channels is formed between a pair of channel rails, the raised portions including the channel rails, a portion of the support surface being formed from upper surfaces of the channel rails.

17. The assembly of claim 16, wherein the support surface formed from an upper surface of the raised portions is pitched downward from the front side toward the rear side of the floor.

18. The assembly of claim 16, wherein the support surface formed from an upper surface of the raised portions is configured to be leveled to a horizontal plane upon installation, and an upper surface of the slab is pitched downward from the front side toward the rear side of the floor.

19. The assembly of claim 16, wherein the raised portions further include raised pads positioned between the perimeter rails and the drain hole.

20. The assembly of claim 13, wherein the slab is a stone slab.