Modular shower pan

A modular shower pan includes at least four polygon panels adapted to interlock in side by side relation to form a body. Each panel has a planar bottom surface and a top surface that is sloped based upon a pre-selected drain position on the body.

FIELD

The present invention relates to a shower pan that is modular.

BACKGROUND

Shower pans must have a correct slope for proper drainage. Conventional systems use mortar laid over an underlying waterproof liner. An integrated waterproofing system that includes a polystyrene floor pan is marketed by Schluter Systems in standard sizes.

SUMMARY OF THE INVENTION

According to the present invention there is provided a modular shower pan. The modular shower liner comprises at least four polygon panels adapted to interlock in side by side relation to form a body. Each panel has a planar bottom surface and a top surface that is sloped based upon a pre-selected drain position on the body.

DETAILED DESCRIPTION

A modular shower pan generally identified by reference numeral10, will now be described with reference toFIG. 1 through 8.

Structure and Relationship of Parts

Referring toFIG. 1-3, a modular shower pan10comprises square panels12(although other polygon shapes could be used) that interlock in side by side relation to form a body14. As shown inFIG. 4, each panel12has a planar bottom surface16and a top surface18that is sloped based upon a pre-selected drain position20on body14. Each panel12has an interlocking profile22made up of a plurality of interlocking bulbous projections (keys)23and recesses (locks)24along each side26, as detailed inFIG. 5. As shown inFIG. 8, there are glue channels28in each interlocking bulbous projection22and recess24that extend between top surface18and bottom surface16of each panel12to facilitate securing side edges26of panels12. Referring toFIG. 6, each glue channel28is made up of a semi-circle30that lines up with a corresponding semi-circle32on an adjacent panel12to form glue channel28. On the inside surface of each glue channel28, there are ribs34that create a larger bonding surface, and allow for greater bonding strength. Referring to5, there is also peripheral scoring36on each panel12to create a frangible connection which allows bulbous projections22to be broken off to leave a planar edge free from interlocking profile22. As shown inFIG. 7-8, an octagon pattern38covers both sides16and18of each panel12to provide a better bond to cement or other adhesives when bottom surface16is installed on a sub-floor, and when a waterproof membrane is installed on top surface18.

Operation

Referring toFIG. 2, the method of installation for modular shower pan10begins by measuring the installation dimensions where shower pan10is to be installed. For a rectangular shaped shower area40, this would include the length and width. While a rectangular shape has been shown as an example, pans for floors with other shapes are also possible. If shower area40is a shape that is not rectangular, then the dimensions would include the shape and size of floor40based on its outer profile44. The size of drain20and its relative positioning within shower area40are also determined. The dimensions are then input into a computer, and software is used to calculate an appropriate slope42for modular shower pan10to ensure proper drainage to drain20. Referring toFIG. 1, body14of panels12are temporarily interlocked. The dimensions of body14include enough panels12to completely cover the dimensions of shower floor40(generally four or more). Referring toFIG. 2, a machine then mills slope42onto top surface18of body14to ensure proper drainage to drain20. A score line46indicating required drain position20is milled into top surface18of body14. An edge43demarking outer profile44of shower area40is then trimmed, so that shower pan10is shipped in the form illustrated inFIG. 3. At a job site, an installer removes panels12from their shipping container and assembles panels12to reform body14by interlocking bulbous projections22of one panel with recesses24of an adjoining panel. As each panel12is installed, it is glued with adhesive to floor area40, with octagon pattern38, illustrated inFIG. 5, assisting with such adhesion. In addition, a glue, such as thinset, is used along interlock22. Referring toFIG. 6, glue channels28secures interlock22against separation. A waterproof membrane is then installed over top surface18to create a water seal.

In some installations, the entire floor area must be raised. In such instances, additional individual panels are shipped which are used to raise the floor. Referring toFIG. 5, during installation, individual panels are trimmed in situ by the installer who breaks off bulbous projections22along peripheral scoring36on each panel12to leave a planar edge free from interlocking profile22for positioning along a wall.

Modular shower pan10, as described in this patent document is designed to be used with existing shower systems, such as the Schluter Shower System and all its components. It is not limited to standard sizes, as each installation is a custom installation to a particular shape and drain position. When used, modular shower pan10eliminates the need for the extensive heavy labour required to install traditional mortar shower pans. After the dimensions of shower floor40are taken and the milling of each panel12is completed, panels12are boxed and brought to shower area40to be installed. Because of their light weight and interlocking design, modular shower pan10can be rapidly installed, usually in less than 20 minutes, as opposed to five to seven hours with mortar pans. An additional advantage of this system over traditional mortar shower pans includes the fact that there is no need to pre-slope shower floor40, and no need for a plumber to be present during installation.