Abstract:
A prefabricated plumbing system or wall system for a shower includes a support frame, a plumbing system carried by the support frame and an enclosure member for enclosing the plumbing system within the support frame. The plumbing system includes a piping configuration for carrying a plurality of body spray mountings and includes a hot water inlet, a cold water inlet, water mixing valve arrangement and a control valve arrangement. Each body spray mounting supports a body spray unit and forms a jet array consisting of spray units. Control valves control the volume of water supplied to the body spray units and the water volume supplied to the water delivering devices. The prefabricated system is adapted to be manufactured as a unit and then shipped for installation in a shower as a unit. A steam seat arrangement for converting a shower into a steam bath is also provided.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is based on U.S. Provisional Patent Application No. 60/922,752 filed Apr. 10, 2007, on which priority of this patent application is based and which provisional patent application is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention relates to a plumbing system for a shower. More particularly, the invention relates to a prefabricated plumbing system for a shower for installation as a unit in the shower, a wall system for a shower, a pre-plumbed steam seat arrangement for optional use in a shower, and a method for manufacturing a shower. 
         [0004]    2. Description of Related Art 
         [0005]    In the past, showers for residential use required that the plumbing or piping be installed before the walls surrounding the shower are finished since this plumbing or piping is installed within the walls. Prefabricated plumbing partitions or modules have been developed over the years for easy installation in the wall of a building. 
         [0006]    U.S. Pat. No. 3,766,574 to Smid, Jr. discloses a prefabricated plumbing partition having a plumbing assembly encased in a block of cellular polyurethane. The plumbing assembly is intended for installation in a bathroom and contains complete facilities for a water closet, lavatory and combination shower and bathtub, together with associated water supply pipes and vent and soil stacks. Specifically, the assembly includes hot and cold water risers, which supply hot and cold water to the assembly. The cold water riser, via pipes and fittings, supplies cold water to the lavatory and the water closet, and the hot water riser, via pipes and fittings, supplies hot water to the lavatory. 
         [0007]    U.S. Pat. No. 4,457,031 to Moore discloses a modular, pre-plumbed shower unit configured to be affixed to a wall above a bathtub. The shower unit provides a shower head, a tub spout and a control valve handle for water temperature control, all of which extend outwardly from the front of a pre-molded shell, one piece construction which conceals the plumbing. The shower unit further includes a plumbing tree positioned within the shell, and the plumbing tree includes a control valve from which extend upper and lower conduits for respective connection of the shower head and the tub spout. This shower unit provides for rapid installation via a simple connection exteriorly of the wall. 
         [0008]    U.S. Pat. No. 3,611,451 to Armstrong discloses a plumbing module having edge flanges for connection to the studs of a building. The module includes a plurality of interconnected pipes. The pipes and edge flanges are joined by an integrally formed web, and the end flanges are provided with suitable openings for the passage of hot and cold water pipes. 
         [0009]    U.S. Pat. No. 2,653,357 to Sanders et al. discloses a prefabricated plumbing installation in which the conduits and connecting pipes of the plumbing system are retained entirely within a supporting framework capable of forming a wall structure. The plumbing installation may be installed as a wall between two rooms or against an existing wall to provide plumbing for the room. 
         [0010]    U.S. Pat. No. 6,834,401 to Hatrick-Smith discloses a shower door system including a door and one or more return panels for forming a shower enclosure. The shower door system further includes a pre-installed shower mixer valve and a pre-installed shower rose mounted in a frame member. Pre-installed plumbing is provided within the frame member to couple the mixer valve to the shower rose. Accordingly, when the shower door system is assembled and installed against a wall to form a shower enclosure, water supply plumbing to the shower may pass from the wall directly to the frame member to connect to the shower mixer valve. 
         [0011]    None of the above references discloses a prefabricated, pre-plumbed shower frame which carries a plumping system that includes a hot water inlet, a cold water inlet, a water mixing valve, a plurality of outlets and several control valves, and in which a frame is adapted to form a wall of the shower. 
         [0012]    There is a need to provide a prefabricated plumbing system for a shower including a pre-plumbed shower frame which can be easily installed and which includes a hot water inlet, a cold water inlet, a water mixing valve, a plurality of water outlets, such as spray mountings or shower heads, and several control valves for controlling the water being delivered to the water outlets, and in which a frame is adapted to form a wall of a shower. 
         [0013]    There is also a need to provide a pre-plumbed steam seat arrangement for a shower which easily converts a shower or bath into a steam bath. 
       SUMMARY OF THE INVENTION 
       [0014]    The present invention has met the above needs. The present invention provides a prefabricated plumbing system or a wall system for a shower that includes a support frame, a plumbing system carried by the support frame and a protective enclosure member for enclosing the plumbing system and a piping network within the support frame, wherein the plumbing system includes a piping configuration for carrying a plurality of body spray mountings, a hot water inlet, a cold water inlet, a water mixing valve arrangement and a control valve arrangement, wherein each body spray mounting supports a shower fixture, e.g. a body spray unit and wherein the prefabricated plumbing system is adapted to form an enclosure for its positioning behind a wall of the shower. 
         [0015]    The present invention also provides a pre-plumbed steam seat arrangement which can be optionally installed in a shower and which includes a support frame, a steam seat on the support frame, a steam generator housed in the support frame for generating steam, a power supply line for the steam generator, a water supply line for supplying water to the steam generator, a control and temperature sensor, and a timer for setting the control to supply steam to the steam seat arrangement at predetermined times. 
         [0016]    The piping configuration for the prefabricated plumbing system or wall system for a shower may contain either four or six body spray mountings for providing four or six jets forming a jet array, and the four or six body spray mountings may be serviced by either a two-control valve arrangement or by a three control valve arrangement. Optionally, for the two-control valve arrangement, one control valve may be used to control the water supply to the body spray mountings, and the other control valve may be used to control the water supply to a further water delivering device, for example, a shower head. For the three control valve arrangement, one control valve may be used to control the water supply to the body spray mountings, and the other two control valves may be used to control the water supply to two shower heads. A water mixing valve, which acts to mix the hot and cold water, supplies the water to the control valves, which, in turn, controls the volume or water supply either to the spray mountings or to one or two additional water delivering devices. 
         [0017]    The present invention also provides a method for manufacturing a shower including the steps of a) providing a prefabricated plumbing system comprising a support frame, a plumbing system including a piping configuration and carried by the support frame, and a protective enclosure member for enclosing the plumbing system within the support frame, and wherein the prefabricated plumbing system is adapted to form an enclosure for its positioning behind a wall of the shower, b) attaching the support frame to a support member, c) connecting the piping configuration to a hot water supply line and to a cold water supply line, and d) connecting a plurality of shower fixtures and a plurality of control knobs to the piping configuration. Prior to performing step d), a wall is installed over the prefabricated plumbing system. Further steps include manufacturing the prefabricated plumbing system at a plant site and then shipping it to an installation site for installation in the shower; providing the piping configuration with a plurality of body spray mountings for supporting the plurality of body spray units; providing at least four or six body spray mountings; and providing the piping configuration with a control valve arrangement for controlling the water being delivered to the shower fixtures, e.g. body spray units and for supporting the control knobs. 
         [0018]    The prefabricated plumbing system or wall system of the invention may be assembled at the manufacturer&#39;s plant and then shipped as a unit to an installation site for installation as a unit in a wall partition of a building or it can be sent partially disassembled and then fully assembled at the installation site between the wall studs. 
         [0019]    The pre-plumbed steam seat arrangement can be packaged at the manufacturer&#39;s plant and then shipped to the installer for installation in a bath or shower. 
         [0020]    These and other objects of the invention will be better appreciated and understood when the following description is read along with the accompanying drawings and the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is an exploded, perspective view of a prefabricated pumping system of the invention which is carried in a support frame; 
           [0022]      FIG. 2  is an exploded, perspective view illustrating a piping configuration for four body spray mountings for providing a four jet array for the prefabricated pumping system of  FIG. 1 ; 
           [0023]      FIG. 3  is an exploded, perspective view illustrating a piping configuration for six body spray mountings for providing a six jet array for the prefabricated pumping system of  FIG. 1 ; 
           [0024]      FIG. 4  is a perspective view illustrating the prefabricated pumping system of  FIG. 1  installed between wall studs; 
           [0025]      FIGS. 5   a - 5   b  are partial, elevational views illustrating an enclosure member for enclosing the pumping system of  FIG. 1 ; 
           [0026]      FIG. 5   c  is a partial, perspective view illustrating an enclosure member of  FIGS. 5   a - 5   b;    
           [0027]      FIG. 6  is a perspective view illustrating a body spray unit used in the pumping system of  FIG. 1 ; 
           [0028]      FIGS. 7   a ,  7   b  and  8  are perspective views illustrating the steps for installing a body spray unit of  FIG. 6  onto each of the body spray mountings of  FIG. 1 ; 
           [0029]      FIG. 9  is a perspective view of a pre-plumbed steam seat arrangement of the invention for optional installation in a shower; and 
           [0030]      FIG. 10  is a perspective view showing the pre-plumbed steam seat arrangement of  FIG. 9  and the prefabricated pumping system of  FIG. 4  installed in a shower. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]    An embodiment of the invention relates to a pre-fabricated plumbing system for a shower or to a wall system for a shower which includes a plumbing system  10 .  FIG. 1  illustrates the plumbing system  10  which includes a support frame  12 , a two-way control valve arrangement  14 , a three-way control valve arrangement  16  and a piping configuration  18  which in this  FIG. 1 , supports six spray mountings  20 . Support frame  12  may be a polymeric or plastic molded frame and includes protruded members or supports  22  which are formed in support frame  12  during the molding process of support frame  12 . Protruded members or supports  22  contain tapped-in holes  24  which correspond to openings  26  provided in extensions  28  which form a base  30  for each of the spray mountings  20 . When assembled, each base  30  of piping configuration  18  abuts against one of the protruded members  22  and is fixedly mounted via suitable fasteners (not shown). 
         [0032]    Still referring to  FIG. 1 , it is to be appreciated that either the two-way control valve arrangement  14  or the three-way control valve arrangement  16  may be used with the piping configuration  18  with the six spray mountings  20 , depending on other water supply requirements for the plumbing system for the shower. For example, if two shower heads are to be provided, then the three-way control valve arrangement  16  would be used. In this instance, a control valve  16   a  would control the volume of water being supplied to the spray mountings  20  and control valves  16   b  and  16   c  would control the volume of water being supplied to each of the two shower heads (not shown). If one shower head is to be provided, then the two-way control valve arrangement  14  would be used. A control valve  14   a  would control the volume of water being supplied to the six spray mountings  20  and a control valve  14   b  would control the volume of water being supplied to the single shower head (not shown). 
         [0033]    The body spray mountings  20  of  FIG. 1  preferably support a shower fixture, such as a body spray unit  80  ( FIG. 6 ) such as that referred to as VECTRA™ Body Spray Jets for an optimum performance of the shower wall system of the invention. These spray units are commercially available from Jacuzzi, Inc., in Chino, Calif. 
         [0034]    The three-way control valve arrangement  16  further includes a thermostat water mixing valve  16   d  which supplies a mix of hot and cold water to the control valves  16   a ,  16   b  and  16   c  through fittings  32 ,  34  and  36  and which mixing valve  16   d  has a cold water inlet  38  and a hot water inlet  40 . Similarly, the two-way control valve arrangement  14  has a thermostat water mixing valve  14   c  which supplies a mix of hot and cold water to the control valves  14   a  and  14   b  through fittings  42 ,  44  respectively, and which mixing valve  14   c  has a cold water inlet  46  and a hot water inlet  48 . 
         [0035]    As shown in  FIG. 1 , three-way control valve arrangement  16  also has a conduit  15  which extends from the fitting for control valve  16   a . This conduit  15  is connected to a top pipe  52  of the piping configuration  18  via a nut  54 . Two-way control valve arrangement  14  also has a conduit  56  extending from the fitting for control valve  14   b , and this conduit  56  is connected to the top pipe  52  of the piping configuration  18  via nut  54 . 
         [0036]      FIG. 2  illustrates a piping configuration  58  having four spray mountings  20  and which piping configuration  58  forms a four-jet sidewall system. Alternatively, the piping configuration  18  of  FIG. 3 , which is the same configuration discussed hereinabove with regard to  FIG. 1 , may be used. This piping configuration  18  of  FIG. 3  forms a six-jet sidewall system. As  FIGS. 2 and 3  illustrate, the support frame  12  can easily accommodate both piping configurations  18  and  58 . For piping configuration  58  of  FIG. 2 , the upper four protruded members  22  will be used for affixing the piping configuration  58  of  FIG. 2  to support frame  12 . For the piping configuration  18  of  FIG. 3 , the six protruded members  22  will be used to affix piping configuration  18  to support frame  12 . 
         [0037]      FIG. 4  illustrates plumbing the system  10  with a three-way valve control arrangement  16  ( FIG. 1 ) and piping configuration  18  ( FIG. 3 ) mounted in frame  12 , which, in turn, is mounted between vertical wall studs  60 ,  62 . Support blocks  64  are provided between wooden wall studs  60 ,  62  for rising and supporting frame  12  on a horizontal stud  63 , and water supply lines  66 ,  68 , and temporary water shut-off valves  70 ,  72  are provided. Shims (not shown in  FIG. 4 ) may be used to provide a comfortable fit between frame  12  and wall studs  60 ,  62 . Also as shown in  FIG. 4 , several pipe nipples  74  are inserted into the spray mountings  20 . These pipe nipples  74  are used to prevent debris from entering into spray mountings  20  and the piping configuration  18  while a wall is being built to close in the plumbing system  10  of the invention. Once a wall is constructed in front of the prefabricated plumbing system or wall system  10 , the pipe nipples  74  can be removed, more about which is discussed hereinbelow. 
         [0038]    Referring to  FIG. 5   a , the wall studs  60 ,  62  may be about 2 inches thick and 4 inches wide. Support frame  12  may have a depth of 3 inches so that the wall studs  60 ,  62  overhang frame  12  by about 1 inch. As also shown in  FIG. 5   a , pipe nipples  74  also extend beyond wall studs  60 ,  62  for their easy removal from spray mountings  20  (not shown in  FIG. 5   a ).  FIG. 5   b  shows that a cement board  76  may be nailed to studs  60 ,  62  and that this cement board  76  may contain a finish material, such as tile, marble or granite, indicated at reference number  77 . Preferably, the finished wall thickness ranges between 4.50 inches to about 6.00 inches.  FIG. 5   c  illustrates a protective enclosure member  78 . This protective enclosure member  78  may be made of a sturdy material, such as a thermoplastic, and may be affixed to the horizontal stud  63  and wall studs  60 ,  62  of  FIG. 4  for protecting the plumbing system  10  when the wall for the shower is being built. 
         [0039]      FIG. 6  illustrates the body spray unit  80  which may be mounted onto each of the spray mountings  20  of  FIG. 1 . Body spray unit  80  of  FIG. 6  may be commercially available from Jacuzzi, Inc. The body spray unit  80  of  FIG. 6  may be installed on one of the body spray mountings  20  according to the procedure illustrated in  FIGS. 7   a ,  7   b  and  8 . As shown in  FIG. 7   a , the pipe nipple  74  in  FIGS. 4 and 5   c  is removed and replaced with a permanent pipe nipple  96  which length extends beyond the finish wall W about 0.50 to 0.75 inch and which outer surface has threads ( FIG. 7   b ).  FIG. 8  shows that the gap between the permanent pipe nipple  96  and wall W is filled with a sealant S. Body spray unit  80  is then installed on pipe nipple  96  to create a water-tight seal in a manner well-known to those skilled in the art. 
         [0040]    In operation, the installer may provide the desired number of spray heads, the location of the spray heads and the controls in the final design of the shower system. Also, the location of the water supply lines may be provided. The installer may provide the final dimensions to the manufacturer for the front wall shower system shown in  FIG. 1 , as well as the back wall system and/or the sidewall system, if utilized. The prefabricated plumbing system  10  of  FIG. 1  can then be easily installed in a shower. Although specific shower arrangements have been disclosed, it is to be understood that a multitude of shower arrangements could be provided ranging from a single shower head to a plurality of shower heads with a variety of controls. 
         [0041]    It can be appreciated that the embodiment of the invention of  FIGS. 1-5   c  provides a prefabricated or pre-assembled plumbing system for a shower whereby a plumber is not needed to plumb the components of the shower system. Instead, the prefabricated system  10  of the invention can be pre-assembled at the manufacturer&#39;s plant and then sent to the installer for installation. 
         [0042]    A second embodiment of the invention provides a pre-plumbed steam seat arrangement  200  of  FIG. 9  that can easily be installed in a shower. The pre-plumbed steam seat arrangement  200  may optionally be installed in a shower enclosure  202  and includes a support frame  204 , a seat  206  on the support frame  204 , a steam generator  208  housed in the support frame  204  for generating steam, a power supply line  210  for the steam generator  208 , a water supply line  212  for supplying water to the steam generator  208 , a control and temperature sensor  214 , a drain and valve line  216 , and a timer  218  for setting the control to supply steam into the shower enclosure  202  at predetermined times. This pre-plumbed steam seat arrangement  200  only requires that a plumber hook-up the appropriate water lines and the power lines, and the steam seat arrangement  200  turns a bath or shower into a steam bath. 
         [0043]      FIG. 10  shows the pre-plumbed steam seat arrangement  200  of  FIG. 9  installed in a shower S and the prefabricated pumping system  10  of  FIG. 4  installed behind the wall W of the shower S. The pumping system  10  includes a plurality of shower fixtures, e.g. body spray units  80  and several control knobs  81   a  mounted on control valves  16   a ,  16   b , and  16   c  of  FIG. 4 . It is to be appreciated that the pipe nipples  74  of  FIG. 4  have been removed from spray mountings  20  and replaced with the body spray units  80 . It is to be further appreciated that the body spray units  80  may be replaced with other suitable shower fixtures or spray units available in the marketplace. 
         [0044]    While the present invention has been set forth in terms of specific embodiments thereof, it will be understood, in view of the instant disclosure that numerous variations upon the invention are now enabled yet reside within the scope of the invention. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims now appended hereto.