Patent Publication Number: US-9848742-B2

Title: Level entry shower system

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a shower system having a level entry. 
     Level entry showers are well-known. They are a necessity for many disabled people and a luxury fixture for others. Generally, shower trays either incorporate a ramp into the design or are recessed into the floor such that a wheelchair or bath chair within the showering area is essentially level with the adjacent floor surface. 
     It has previously been proposed to provide a shower tray for a disabled person that has a tray and a removable cover plate supported above the tray on which the wheelchair stands during showering. Run-off water passes through holes in the cover plate and is conducted towards a waste water outlet by the tray. This is not ideal due to the size, strength, and durability required for the cover plate, making the cover plate heavy and thus difficult to remove for cleaning the tray. 
     Other shower trays for level entry showers incorporate a raised central portion and a wastewater channel for directing the runoff to a drain. These may be difficult to properly clean and also potentially difficult to install due to the location of the drain toward the outside edge of the shower tray. Still other shower trays comprise curbs around the exterior of the tray, which increases the difficulty and expense of installation as ramps have to be incorporated. Shower trays having no curb or barrier on the entry side are also known, but those often do not provide sufficient slope to ensure proper drainage without the use of some other means to prevent the wastewater from escaping the area. 
     Additionally, there have been a number of installation issues in the currently known drain assemblies for level entry shower systems. These systems comprise parts that are difficult to correctly install or require the investment of a significant amount of time for installation. 
     Those offering the sale and/or installation of known systems generally must stock several different shower pan sizes in order to accommodate the wide range of shower sizes. 
     Embodiments of the present invention seek to overcome some or all of these problems by providing a curbless, stepped shower tray appropriate for a wide range of shower sizes and an easy to install drain assembly. 
     SUMMARY OF THE INVENTION 
     Embodiments of the inventive shower system provide for a level entry with no curb to step over to enter the showering area. They incorporate certain design improvements over other systems for streamlined and improved installation. Several embodiments of the system comprise a shower tray and drain assembly. The tray comprises a stepped upper surface and a receptor having at least one step for receiving the drain assembly. In certain embodiments, the drain assembly comprises a cup for securing the drain assembly to the receptor and to a drainage pipe, a clamping flange for securing a waterproof floor covering between the clamping flange and the cup, at least one gasket for providing a watertight seal between the drainage pipe and cup. The drain assembly may further comprise a grate, a grate retainer, and an adjuster for adjustably securing the grate retainer to the clamping flange. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a top perspective view of an embodiment of a shower tray. 
         FIG. 2  depicts a bottom view of the shower tray embodiment shown in  FIG. 1 . 
         FIG. 3  provides a perspective close view of an embodiment of the receptor. 
         FIG. 4  shows a perspective view of an embodiment of a drain assembly cup. 
         FIG. 5  shows a side view of the cup depicted in  FIG. 4 . 
         FIG. 6  is a cutaway side view of the cup depicted in  FIG. 4 . 
         FIG. 7  depicts an embodiment of a lock ring configured for use with the cup depicted in  FIG. 4 . 
         FIG. 8  shows a perspective view of an embodiment of a lock ring tightening tool engaged with a lock ring as shown in  FIG. 7 . 
         FIG. 9  provides a perspective view of an embodiment of a drain assembly clamping flange. 
         FIG. 10  depicts a side perspective view of the clamping flange depicted in  FIG. 9  and a top perspective view of the cup depicted in  FIG. 4  as installed in a shower tray. 
         FIG. 11  depicts an embodiment of an adjuster configured for use with the clamping flange depicted in  FIG. 9 . 
         FIG. 12  depicts a perspective view of an embodiment of a grate retainer. 
         FIG. 13  provides a perspective view of an embodiment of an assembled drain assembly. 
         FIG. 14  provides a cutaway view of the assembly depicted in  FIG. 13 . 
         FIG. 15  shows a cutaway, exploded view of the assembly depicted in  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     The inventive level entry shower system is described below with respect to non-exclusive embodiments depicted in the figures. The depicted embodiments of the inventive level entry shower system comprise a shower tray  10  and a drain assembly  100 . 
     A. Shower Tray 
     The shower tray  10 , as depicted in  FIGS. 1-3 , comprises a top side having a plurality of steps, an underside having a waffle grid, and a receptor  12 . The stepped design of the top side of the tray  10  should provide for a slope to meet local requirements from the exterior edge to a center drain opening (e.g., 2% slope or 0.25 inches per foot). Upon being installed, the waffle underside of the tray  10  eliminates deflection when weight is placed upon the tray  10 . 
     Although the tray  10  has a fall to the receptor  12  sufficient to allow water to quickly drain, it maintains a thin profile. This profile allows it to be installed on top of structural flooring members, thus eliminating the need to modify an existing floor system, such as by lowering or cutting into the floor supports. The modification of existing floor supports may cause structural damage to the floors, adds time to installation of a shower, and increases the opportunity for mistakes in installation. The tray  10  may be used in structures comprising traditional wood joists, prefabricated wood joists, engineered trusses, or slab on grade concrete foundations. It may also be installed in concrete floors utilizing tension cables when measures are taken into account to avoid cables during installation. 
     The receptor  12  is located in a central area of the tray  10 . The receptor  12  incorporates at least one step for retaining the drain assembly  100  (see  FIGS. 13-14 ). The receptor  12  as shown in the depicted embodiment comprises two steps and may further comprises screw receiving holes  16 ,  16 ′,  16 ″ and a cup engagement tab receiver  14 . 
     Because the tray  10  is curbless, the tray  10  may be easily cut down to accommodate smaller shower designs. For example, it may be manufactured to measure 59.5 inches by 47.5 inches, a standard size for a larger shower, and be designed so that it may be cut down to 48.0 inches by 36.0 inches, a standard size for a smaller shower. 
     Some embodiments incorporate a textured surface for the top side of the tray  10 , which may allow for the creation of a stronger mechanical bond between our tray and waterproofing materials used in installation. 
     In some embodiments, the tray  10  may be manufactured to incorporate cut lines and screw dimples into the top side of the tray  10  to ease installation. The cut lines match with strategically placed supports on the underside of the tray to ensure a solid installation. The screw dimples on the top side of the tray  10  may be strategically located to match up with a thickened area on the underside of the tray. This thickened area prevents screws used to secure the tray  10  to the floor&#39;s framing elements from breaking through the tray  10  before becoming fully installed. 
     A non-exclusive example of a method of installing an embodiment of the invention follows. Language such as “should” is horatory and not mandatory, and is not to be interpreted as limiting the scope of the invention or ruling out other methods of carrying out the invention. 
     Prior to installing the tray  10  in a room having a wooden subfloor and framing, the subfloor where the tray  10  is to be installed is removed. Next, it may be advisable to frame the area underneath the tray  10  such that blocks, such as plywood pieces, are installed between the joists or trusses of the floor&#39;s structural system to provide additional support to the area. A new subfloor, which may be level with the top of the floor&#39;s structural system, may then be installed over the framing elements with an opening in the center section of the shower area where the receptor  12  shall be located. The tray  10  may then be set into position. Any adjustments may then be made to ensure level installation of the tray  10  while making sure the bottom of the receptor  12  is not resting on a block, joist, truss, or other framing element. 
     Once this has been accomplished, a construction adhesive, such as a latex modified thinset or other mortar appropriate to secure, may be applied to the area beneath the tray  10 . The tray  10 , preferably with the drain assembly cup  20  (later described) already installed, may then be set into place on top of the adhesive to be secured to the replacement subfloor. The tray  10  may be further secured to the framing elements using, for example, screws around the perimeter of the tray  10 . 
     The tray  10  may be manufactured from any of a variety of materials, including relatively lightweight but strong materials that are substantially impervious to water. Non-exclusive examples of materials from which the tray  10  may be manufactured include acrylic plastic, ABS or PVC plastic, or fiberglass. 
     Those skilled in the art will appreciate that other methods of installation may also be appropriate, whether the flooring structure is wooden, concrete, or some other material or combination of materials. 
     B. Drain Assembly 
     As may be seen in  FIGS. 4-15 , an embodiment of the inventive drain assembly  100  comprises a cup  20 , lock ring  30 , clamping flange  40 , adjuster  50 , grate retainer  60 , and grate  70 . This drain assembly  100  provides an easy to install, watertight drain for the inventive system. The embodiment of the drain assembly  100  as depicted in  FIGS. 3-14  is compatible with a 2 inch pipe made of PVC plastic. With the use of a corresponding gasket, the assembly  100  may be further compatible with 2 inch ABS plastic, copper, or cast iron pipes by purchasing and using the corresponding rubber drain gasket. The addition of a drain coupling may allow the assembly  100  to be compatible with other types and sizes of pipes as well. The embodiment of the drain assembly  100  is further described below both as to its structure and in association with a non-exclusive example of an installation method. Again, language such as “should” is horatory and not mandatory and is not to be interpreted as limiting the scope of the invention or ruling out other methods of carrying out the invention. 
     The cup  20  is shown in detail in  FIGS. 4-6 . The cup  20  in the depicted embodiment is a stepped fitting with a lower threaded section  21 , for securing the drainage pipe to the drain assembly  100  (further described below) and an upper section  23  for securing the clamping flange  40  (described below) to the cup  20 . The cup  20  may further comprise a cup engagement tab  22  that protrudes below the underside of the cup  20 , providing a means for aligning the cup  20  with the tab receiver  14  of the receptor  12  and for aligning the engagement tab  46  of the clamping flange  40  (described below). The cup  20  may comprise a plurality of mounting screw holes  24 ,  24 ′,  24 ″, which may be utilized in securing the cup  20  to the receptor  12  using a plurality of screws  25 ,  25 ′,  25 ″. The cup  20  may further comprise a plurality of clamping flange mounting screw holes  26 ,  26 ′,  26 ″, also used in installing the clamping flange  40 . 
     The cup  20  may be installed by securing it to the receptor  12  of the shower tray  10 . A seal, such as a gasket or an o-ring, may be placed between the receptor  12  and cup  20  to provide a watertight seal. In addition or in the alternative, the underside surface of the cup  20  coming into contact with the receptor  12  may be coated with a sealant, such as silicone or caulk. The cup  20  may be set into the receptor  12  and rotated until the engagement tab  22  of the cup  20  fits into the engagement tab receiver  13  (see  FIG. 14 ) of the receptor  12 . Use of the engagement tab  22  and receiver  13  ensures that the cup screw holes  24 ,  24 ′,  24 ″ will be properly aligned for installing the screws  25 ,  25 ′,  25 ″ through them and into the screw holes of the receptor  12 . 
     Upon securing the tray  10  to the framing elements, the cup  20  fits securely to a drainage pipe. An adapter, such as a gasket  28  or drain adapter (not shown), may be installed between the cup  20  and a drainage pipe (not shown) to form a watertight seal. Drain adapters may take various forms depending on the type of pipe that is to be attached to the shower system. It may be advisable to use a suitable lubricant to aid in placement of the gasket  28 . It may also be advisable to use watertight adhesive or sealant, such as latex caulk, between the cup  20  and the drain pipe or the drain adapter. It may further be advisable to utilize a secondary method of securing a drain adapter to the cup  20  such as by screwing the adapter to the cup  20 . At this point, the tray  10 , the perimeter around the tray  10 , and the lower portion of the shower walls may be prepared for the installation of a waterproofing compound, such as a waterproofing membrane, over a waterproofing fabric, or a waterproof sheet membrane. After inspecting and testing for water tightness, selected flooring, such as tile, may be installed. 
     As shown in the depicted embodiment, a lock ring  30  and drain gasket  28  provide a watertight seal between the cup  20  and drainage pipe (not shown) without the use of caulk or other sealant, thereby providing for faster and more reliable installation.  FIGS. 7 and 8  show an embodiment of a lock ring  30  and lock ring tightening tool  34 . The embodiment of the lock ring  30  as shown comprises a rubber gasket with optional tightening tab receivers  31 ,  31 ′,  31 ″,  31 ′″. The drain gasket  28  as depicted in  FIG. 15  comprises a standard rubber gasket. 
     The applicant has devised an inventive multipurpose tightening tool, an embodiment of which is depicted as tightening tool  34 , to assist in the installation process of the drain assembly  100 . In the depicted embodiment, tightening tool  34  is cylindrical in shape and has two slots  35 ,  35 ′ formed in the wall of the shaft at a first end thereof, each slot being substantially opposite the other slot; two handles  36 ,  36 ′ extending outward from the outer surface of the wall substantially adjacent the first end of the shaft, each handle being substantially opposite the other handle; helical threads along the outer surface at the second end thereof, the helical threads being configured to engage the drain gasket lock ring  30 ; and preferably at least three tabs (two of which,  38 ,  38 ′ are shown) located substantially equidistant around the circumference of the outer wall of the shaft adjacent the helical threads, the tabs being configured to engage the tab receivers  31 ,  31 ′,  31 ″,  31 ′″ of drain gasket lock ring  30 . The inventive tightening tool can be helpful in installation of the drain assembly, for example when used to install the cup  20 , gasket  28 , and lock ring  30  as described hereafter. Using the inventive tightening tool speeds the installation process and, because of its unique configuration, the inventive tightening tool is unlikely to become lost or to fall into an open drain pipe during the installation process, thus avoiding a common problem of existing installation tools. 
     After installing the cup  20  in the tray  10  and securing the tray  10  to the floor, a gasket  28  (see  FIG. 15 ) may be set inside the threaded section  21  of the cup  20 . The tightening tool  34  may be used to position and press into place the gasket  28  so that it is fully seated in the lower threaded section  21  (see  FIGS. 4-6 ). The tightening tool  34  may then be used to seat the lock ring  30  in the upper portion  23  of the cup  20  so that it is frictionally engaged with the interior surface of the cup  20 . Once the lock ring  30  has been set in place, the tool  34  may be used by grasping the handles  36 ,  36 ′ or the upper area of the tool  34 , aligning the tightening tab receivers  31 ,  31 ′,  31 ″,  31 ″′ with the tightening tabs  38 ,  38 ′, and firmly pressing down on the handles  36 ,  36 ′ or the top edge of the tool  34 . In the alternative, the tool  34  may be used by inserting a substantially rigid elongated member into the slots  35 ,  35 ′ and using the elongated member to press or twist the tool  34  to align the tightening tab receivers  31 ,  31 ′,  31 ″,  31 ″′ with the tightening tabs  38 ,  38 ′. 
     At this point, any waterproofing steps may be completed. For example, the area surrounding the tray  10  may be covered with a waterproofing compound, such as a waterproofing membrane, over a waterproofing fabric, or a waterproof sheet membrane may be used. The seams at the floor and corners may be taped and then an additional waterproofing layer may be applied over the entire shower floor area, including overtop the shower tray  10 . 
     Once the waterproofing is complete, a circular opening may be cut into the waterproofing materials at the site of the drain assembly  100 . As may be seen in  FIGS. 9-10 , the clamping flange  40  may then be installed. The clamping flange  40  comprises a plurality of screw holes  42 ,  42 ′,  42 ″, a plurality of outer weep holes  44 ,  44 ′,  44 ″, a plurality of inner weep holes  45 ,  45 ′,  45 ″, and a clamping flange engagement tab  46 . These inner and outer weep holes  44 ,  44 ′,  44 ″,  45 ,  45 ′,  45 ″ align with small drain channels  48 ,  48 ′ located on the bottom and side wall of the clamping flange  40 . These channels  48 ,  48 ′ continues down the wall of the clamping flange  40  and terminates just above the bottom flange of the cup  20 . This drainage path allows any water that penetrates the flooring or grout areas to drain into the drainage pipe. 
     To install the clamping flange  40 , the clamping flange  40  is set into the cup  20  and turned until the engagement tab  46  is aligned with the cup engagement tab  22 . This alignment of the tabs  22 ,  46  provides a desirable alignment of the clamping flange mounting screw holes  26 ,  26 ′,  26 ″ of the cup  20  and the clamping flange mounting screw holes  42 ,  42 ′,  42 ″ of the clamping flange  40 . In order to achieve a watertight seal, the waterproofing materials may be cut such that they fit under the outer edge of the clamping flange  40 . When screws are inserted and secured in the screw holes  26 ,  26 ′,  26 ″ and through screw holes  42 ,  42 ′,  42 ″, the waterproofing materials are pressed between the top rim  27  of the cup  20  and the top rim  47  of the clamping flange  40 . 
     The drain assembly  100  further comprises a three piece strainer system consisting of an adjuster  50 , grate retainer  60 , and grate  70 , which are shown in  FIGS. 11-14 . The adjuster  50  may be threaded into the clamping flange  40  and serves to receive and hold in place the grate retainer  60 . The grate retainer  60 , in turn, secures the grate  60 . The grate retainer  60  may comprise a small channel  61  within which an o-ring  68  (see  FIG. 15 ) or other seal may be placed. Such a seal may assist in mating the adjuster  50  and grate retainer  60  and also aid in a watertight seal between the pieces should the attached drainage system ever back up. 
     This three piece system is particularly useful in that it allows for lowering the grate retainer  60  after the shower flooring has been installed. In the event that the strainer has to be lowered during floor installation, the grate retainer  60  may be disengaged from the adjuster  50 , the adjuster  50  may be screwed down to provide a lower profile, and the grate retainer  60  may be re-installed. 
     The grate  70  and grate retainer  60  may further comprise some means for connecting the two such that the grate  70  will be held in place but may be removed for cleaning. For example, in the embodiment depicted in  FIG. 12 , the grate retainer  60  may have a plurality of tabs  62 ,  62 ′ which pair with openings in the underside of the grate  70  (not shown). 
     The grate retainer may further comprise tile tabs  64 ,  64 ′ around its perimeter to ensure an equal tile joint distance around the retainer  60  where the edges come into contact with tile. 
     Following the complete installation of the drain assembly  100 , flooring for the shower area, such as tile or vinyl, may then be installed. Should it be determined that the grate  70  and grate retainer  60  were initially installed at the incorrect height, they may be removed and reinstalled at the correct height. 
     The foregoing details are exemplary only. Other modifications that might be contemplated by those of skill in the art are within the scope of this invention, and are not limited by the examples illustrated herein.