Abstract:
A Doorless Shower Enclosure System is a water handling system for human showering which is configured in such a way as to fit into an alcove in a bathroom of approximate size as that of a bathtub, and effectively contain and discharge water from a shower head, without the use of a physical door. The system is composed of a prefabricated base with a drain, a glass partition, and a metal crossbar support. The glass partition rests upon the base and is supported at the top by the metal cross bar, which is mounted to the side walls of the alcove. Access to the shower compartment is through a walk-in opening, as opposed to an operable door.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority on U.S. Provisional Patent Application No. 61511143 filed Jul. 25, 2011, the contents of which of which are hereby incorporated by reference into this application in their entirety. 
     
    
     STATEMENT REGARDING FEDERALLY SUPPORTED RESEARCH 
       [0002]    Not Applicable. 
       REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM 
       [0003]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    The present invention relates to prefabricated shower bases, shower stalls and/or shower enclosures. 
         [0006]    2. Description of Related Art 
         [0007]    There are numerous examples of square or rectangular shaped prefabricated shower bases such as that described in U.S.P.T.O. Application No. 20040034922 filed Feb. 26, 2004. These examples describe prefabricated shower bases which are configured differently and are manufactured by differing methods using differing materials. They are intended to be installed on the floor of a bathroom in alcoves composed of three contiguous, conventionally built walls. They are configured to allow for walk in access on one side and to convey water from shower use into an integral drain hole. When installed as intended in a three sided alcove, they do not contain a means to prevent water spray from shower use, from traveling beyond the base to the outside of the alcove, or shower enclosure. They rely upon the independent installation of a shower curtain, access door, or partition with an access door, to prevent escape of water spray through the open side of the shower enclosure. 
         [0008]    The prefabricated shower base part of the subject invention is a similar embodiment to that shown on catalog sheet titled “Florentine Model: Rectangular-Single Threshold” Precast Terrazzo Shower Floor Architectural Specifications, by Creative Industries Terrazzo Products, Inc., 1753 North Spaulding, Chicago, Ill. 60647. 
         [0009]    The product referenced in [0006] is a rectangular shaped, prefabricated base which is intended to be installed on the floor of a bathroom, in an alcove or shower stall, composed of three contiguous walls. It is a solid casting of terrazzo on which the user stands, the surface of which is sloped toward a drain hole provided for discharge of water from showering. When installed as intended, it prevents leakage from water which has traveled down the walls of the alcove and contacted the base, and directs it across the walking surface of the base into an integrally constructed drain. The maximum length, or long dimension of the rectangular shaped base, that this product is manufactured to is 60″, which is the length of a bathtub. The side of the base located at the open side of the shower stall contains a 4″ tall curb. This curb prevents water which has accumulated on the floor surface of the base, from escaping and allows for walk in access into the shower stall. 
         [0010]    The product referenced in [0006] does not contain provisions for containment of water spray from the showering process on the access side of the shower stall and relies on the independent installation of a shower curtain, or solid partition with a door, to contain water spray and direct it into the base. 
         [0011]    There are numerous examples of glass panel shower wall systems such as that described in U.S.P.T.O. No. D321755, U.S. Pat. No. 7,346,939, and U.S. Pat. No. 7,849,531, which include door assemblies. These products are vertical partitions which are independent of, and do not contain a shower base, and thus, do not represent a complete water handling system for the showering process. 
         [0012]    There are also numerous examples of prefabricated shower compartments which contain walls, bases, and are made of fiberglass or other synthetic materials such as that described in U.S. Pat. No. 4,578,832. These prefabricated compartment typically rely upon the independent installation of a shower door or shower curtain to contain water spray from showering. U.S. Pat. No. 4,215,444 is an example that is configured so as not to require a door. 
         [0013]    3. Problems Associated with Related Art 
         [0014]    The shower bases referenced in [0005] and [0006] do not confine water spray from the shower while in use and require the installation of an independent element such as a shower curtain or door, or a partition which includes a door. They do not represent a complete water handling system for the showering process. 
         [0015]    There are numerous problems associated with shower stalls that utilize prefabricated shower bases and independently installed shower curtains such as those noted in [0012], including but not limited to, leakage of water spray, difficult drying conditions, maintenance of shower curtains, light blockage, and poor air circulation during shower use. 
         [0016]    There are numerous problems associated with shower stalls such those noted in [0012], that utilize prefabricated shower bases and independently installed shower stall partitions with doors including but not limited to, complex fabrication and installation process; difficult to execute a positive, long term water seal between the base and partition; leaking partition assemblies; leakage at sliding or hinged type doors; poor air circulation while showering; and difficulty in the drying of the shower stall after use. 
         [0017]    The common problem associated with the glass panel shower wall systems referred to in [0009] is that they rely on the independent installation of a shower base and do not represent a complete water handling system for the showering process. They rely on the selection of an appropriate base and do not make accommodations to adapt to any particular base. This procedure does not guaranty that there will be a watertight joint between the separate wall and base products and that leakage will not occur. Since the base is not designed to accommodate a specific door product, leakage often occurs at the door after such a product is installed. 
         [0018]    The problem common to most of the prefabricated shower compartments referred to in [0010] is the lack of a shower door, requiring the installation of an independent shower door or curtain. They do not make accommodations for these independent elements and there is no assurance that those installed will result in a leak free final installation. U.S. Pat. No. 4,215,444 is a prefabricated shower compartment which is configured so as not to require a door or curtain. The problems associated with it are its large size, lack of air circulation, and that its configuration blocks light from the adjacent room, requiring separate lighting inside the shower compartment. 
       BRIEF SUMMARY OF THE INVENTION 
       [0019]    This invention employs a prefabricated shower base and a fixed plate glass partition, which are configured to fit together in a leak free manner so as to confine water spray from showering without the necessity of an operable access door or shower curtain. This invention is intended to be installed on the floor of a bathroom, in an alcove or shower stall, composed of three contiguous conventionally built walls which are constructed by others. The size of the alcove is similar to that required by a bathtub. The doorless configuration eliminates the many problems associated with operable doors and shower curtains. 
         [0020]    The doorless shower enclosure system is intended to be installed in an alcove as described in [0017]. The depth of the alcove is similar to that required by a bathtub. The width of the alcove is determined by the width of the fixed glass panel required to confine the spray from showering, and the minimum opening width required for easy access into the shower stall. The dimensions of length and width of the shower stall and the prefabricated base of the doorless shower enclosure sysytem are determined by these factors. 
         [0021]    The prefabricated base is installed on the sub-floor of a three sided alcove, or shower stall, in a building. The glass partition is installed after installation of the base and construction of the adjacent walls of the shower stall is completed. A drain line installed by others, is connected to the drain in the base to facilitate the discharge of water. 
         [0022]    The prefabricated base is configured in such a manner that it contains a recess in the top of the curb at the open side of the shower stall, to allow for the bottom of the glass panel to interlock with the base in a ‘male/female’ manner and for the installation of sealant to create a positive water seal. 
         [0023]    The top of the glass panel is supported by a metal cross bar, which is installed in conjunction with the glass panel, and which extends across the open side of the shower stall. The cross bar support is attached to the adjacent side walls. The height of the top of the glass panel and cross bar, is similar to the height of a standard walk door, which allows for walk in access to the shower enclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0024]      FIG. 1  is a perspective view of a doorless shower enclosure system installed in an alcove with three contiguous walls which is constructed by others. 
           [0025]      FIGS. 2A ,  2 B, and  2 C compose an orthographic projection of the doorless shower enclosure system and are a top view, front view, and right side view, respectively.  FIG. 2D  is a section view taken as shown on  FIG. 2B . 
           [0026]      FIG. 3A  is a perspective view of the prefabricated base  10  of the doorless shower enclosure system.  FIG. 3B  is a cross section of the base which is taken in  FIG. 3A  as indicated.  FIG. 3C  is an enlarged detail view of the threshold side of the prefabricated base as indicated in  FIG. 3B .  FIG. 3D  is an enlarged detail view of the perimeter curb of the base, which is typical to the three sides which are contiguous to shower stall walls as indicated in  FIG. 3B . 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    In the following description, specific details are set out to provide examples of the claimed subject matter. However, no embodiment described below is intended to define or limit the claimed subject matter. It should be apparent to those skilled in the art that many variations of the provided examples may be possible within the claimed subject matter. 
         [0028]    Referring specifically to the drawings, in  FIG. 1  a doorless shower enclosure system is shown in a perspective view. Its components are: a prefabricated base  10  with a drain and drain cover  13 , a glass panel  12 , and a metal cross bar support  11 . A doorless shower enclosure is installed in an alcove constructed by others, with three contiguous walls  14  and a floor  15 . It is installed so that the glass panel  12  and the drain cover  13  in the base, are located adjacent to the wall  14  where the shower head  17  is located. All plumbing, including the shower head  17 , is installed by others. The space shown under cross bar  11  and at the right side of the glass panel  12 , is open to allow for access into the shower stall. 
         [0029]    The plan area size of the shower enclosure shown in  FIG. 1  is as noted in [0017] and the corresponding size of the base noted in [0018], is intended to relate to the plan area size of a bathtub. The specific width of the alcove and the corresponding width of the glass panel are as noted in [0018]. 
         [0030]    Referring to  FIG. 1 , the prefabricated base  10  is installed on top of the floor  15 . The floor  15  can be either conventionally wood framed or a concrete slab and is constructed by others prior to the installation of the base. The walls  14  are conventionally framed stud walls which are constructed by others and may be framed prior to, or after, the installation of the base  10 . After the installation of the base  10 , the construction of the walls  14  is completed by others, with the installation of a sheathing product and a water resistant finish material. After the installation of the base  10 , a plumbing drain line installed by others, is connected to the drain below the drain cover  13 . Upon completion of the construction of the walls  14 , the glass panel  12 , and the metal cross bar support  11 , are installed. 
         [0031]      FIGS. 2A ,  2 B, and  2 C compose an orthographic projection of the doorless shower enclosure system shown in  FIG. 1 , and are a top view, front view, and right side view, respectively.  FIG. 2D  is a section view taken as shown on  FIG. 2B . 
         [0032]      FIG. 2B  is the front view and shows the overall width of the shower stall between walls  14  at the right and left sides. The overall width is determined by the width of the glass panel  12  and the width of the adjacent open space required for easy access, which are proportioned as noted in [0018]. The height of the shower alcove is shown as the distance between the floor  15  and the ceiling  16 . The height of the top of the glass panel  12  and cross bar support  11  above the floor  15 , corresponds closely to that of a standard walk door, allowing for adequate head clearance during walk in access through the opening between the edge of the glass panel  12  and the right side wall  14 . The opening shown above the cross bar support  11  and below the ceiling  16  has a vertical dimension which corresponds to the difference in height of a standard door and the height of the ceiling. The access opening and the opening above the cross bar support allow for effective air circulation, which aids in the elimination of steam during shower use, and drying of the shower compartment after completion of showering. 
         [0033]    Shown in  FIG. 2B , is the cross bar support  11 , which is fabricated from corrosion resistant metal with a cross-sectional shape which accommodates the top of the glass panel  12  in a ‘male/female’ manner. The cross-sectional shape is designed to provide sufficient structural stiffness to resist a horizontal force which might be applied by a person pushing against it or accidentally impacting the glass panel. The ends of the cross bar support are attached to the adjacent walls  14  by metal brackets designed to accommodate the ends of the support bar and allow for attachment to the walls. The design and fabrication of the cross bar support  11  is known to those practiced in the art. The glass panel  12  and cross bar support  11  are installed after construction of the walls is completed. 
         [0034]      FIG. 2B  shows the joint between the glass panel  12  and the surface of the adjacent wall  14  is sealed with waterproof sealant  18 , and the section indicators  2 D. 
         [0035]      FIG. 2D  is an enlarged section view of the joint between the glass panel  12  and the surface of the adjacent wall  14  which is taken as indicated in  FIG. 2B . This joint is shown to be sealed with a waterproof sealant  18  which is installed after the installation of the glass panel  12  and assures the containment of water spray within the shower stall. 
         [0036]      FIG. 2C  is a right side view which shows the depth of the shower stall, between the glass panel  12  at the front, and the rear wall  14 . This dimension is intended to relate closely to that of a bathtub. Also seen in this view is the opening above the cross bar support  11  and the ceiling  16 , which allows for escape of steam and air circulation. 
         [0037]      FIG. 2A  is a top view which shows the plan area of the doorless shower enclosure with dimensions as noted in [0018]. The base  10  is configured so that it is sloped to drain to the drain cover  13  located at the end next to the shower head  17 . The joint between the glass panel  12  and surface of adjacent wall  14  is filled with waterproof sealant  18  to assure that water spray is confined within the shower stall. Cross bar support  11  is shown extending across the open side of the shower stall between left and right sidewalls  14 . 
         [0038]      FIG. 3A  is a perspective view of the base  10 , which relates closely to that described in [0006]. This view shows the perimeter curb around the sides of the base intended to be contiguous with the walls of the shower stall, as well as the threshold curb at the open side. The top surface of the base  10  is shown to be sloped to drain to the drain cover  13  to direct water in the shower stall which is collected by the base, into the drain where it is discharged. Also seen in this view is the wall flange  62  which is continuous around three sides of the base, and the glass support channel  61  located in the threshold curb at the front of the base. 
         [0039]    Also seen in  FIG. 3A , is cross section indicator  3 B, and section view indicators  3 B. 1  and  3 B. 2 . 
         [0040]      FIG. 3B  is a cross section view of the base  10 , as indicated in  FIG. 3A . The top surface of the prefabricated base  10 , is sloped toward the drain body  63  to direct water in the base to the drain, where it is discharged through the drain pipe  64 . The drain pipe  64  is part of the plumbing of the building and is supplied and installed by others. Also shown is the drain cover  13 . The drain body is made of a corrosion resistant material and is fabricated integrally with the base  10  in a manner known to those practiced in the art, to provide a leak free interface between the material of the base and the material of the drain body. 
         [0041]    The portion of  FIG. 3B  that shows the threshold curb is designated view  60 A, as indicated by section view indicator  60 A in  FIG. 3A . View  60 A shows glass support channel  61  and that the top surface of the threshold curb is sloped to drain into the base to contain water within the shower stall. Also shown is enlarged view indicator  3 C. 
         [0042]    The portion of  FIG. 3B  that shows the perimeter curb which is typical to three sides of the base that interface with the wall construction is designated view  60 B, and is indicated by section view indicator  60 B in  FIG. 3A . View  60 B shows the wall flange  62  of the base, and wall construction  81  which is by others. 
         [0043]    The prefabricated base  10  can be made of terrazzo, as is that described in [0006], or other dense, water resistant, abrasion resistant, synthetic material such as Corian by Dupont Co., which is capable of supporting the glass panel and the weight of human foot traffic without deflection or movement. The method of fabrication and materials utilized are known to those skilled in the art. 
         [0044]      FIG. 3D  is an enlarged view of the perimeter curb of the prefabricated base  10  which is typical to three sides of the base that are contiguous with the walls of the shower stall.  FIG. 3D  is referenced in  FIG. 3B  by enlarged view indicator  3 D. Shown in  FIG. 3D  is wall flange  62 , which is made of a corrosion resistant material, and fabricated integrally with the base  12  in a manner known to those practiced in the art, to provide a leak free interface between the material of the base and the material of the wall flange. The wall flange  62  prevents water leakage at the perimeter of the base into the wall framing elements  81 B, which are installed by others. Wall flange  62  extends upward behind the bottom of the wall sheathing and waterproof finish materials  81 A installed by others, to allow for effective overlap. After the base  10  is installed and the wall framing  81 B is completed, wall finish materials  81 A are installed. 
         [0045]      FIG. 3C  is an enlarged view of the portion of the threshold side of the prefabricated base  10 , which supports the glass panel  12  and is referenced in  FIG. 3B  by enlarged view indicator  3 C. Shown is glass support channel  61 , which is configured to allow for the bottom of the glass panel to be installed and be recessed below the top surface of the threshold. The support channel  61  is also configured to allow for the installation of a waterproof sealant  71  all around the base of the glass panel  12  to create a leak free seal between the two elements. The glass panel is installed after completion of the installation of the wall finish materials  81 A, referenced in [0042]. Upon completion of the installation of the glass panel  12 , sealant  18  referenced in [0035] is installed. 
         [0046]    It will be appreciated by those skilled in the art that many variations are possible within the scope of the claimed subject matter. The embodiments that have been described above are intended o be illustrative of the claimed subject matter and not defining or limiting.