Patent Publication Number: US-6990695-B2

Title: Shower pan

Description:
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
   The invention relates to a shower pan for use in a shower stall. Such shower pans act as a base in the shower stall on which the user stands while showering, and includes a drain hole for allowing water to drain out of the shower stall. 
   While shower stalls may be any shape, many are rectangular, having three shower surface walls and a fourth side on which a shower stall door is mounted. An important concern is the prevention of water leakage from the shower stall into surrounding structures outside of the shower stall. In an attempt to prevent leakage, prior art shower pans have utilized a water dam extending upward from the base of the shower pan on all four sides. On the three sides supporting the shower surface walls, a ridge extends upward from the water dam, behind the shower surface walls. The shower door is mounted on the water dam on the remaining side, which does not include a ridge, presumably to allow for the shower door to open and close freely. However, such a configuration allows for water streaming through cracks in the door track on which the door is mounted to escape the shower pan and shower stall as there is no ridge or similar structure to stop the water. It is common for water on the shower door to flow down into the door track. Also, water flowing in between shower surface walls and the drywall behind it flows downward to the water dam, traveling to the front side of the water dam where it contacts the door track. Water seeping through crevices in the door track flows out of the shower stall and can damage surrounding wood structures. Adding sealant is time consuming and not completely effective in stopping leakage. 
   Therefore, there is a need for a shower pan that effectively stops water leakage from a shower stall, particularly the side of the stall in which the door is positioned. In an effort to overcome and eliminate the aforementioned problems, the present invention was conceived. 
   SUMMARY OF THE INVENTION 
   Therefore it is an object of the present invention to provide a shower pan for use in a shower stall that effectively prevents water leakage into structures outside of the shower stall. 
   It is another object of the present invention to provide a shower pan on which a door track can be mounted, and prevents water streaming past the door track from escaping the shower pan, without inhibiting movement of the shower stall door which is mounted on the door track. 
   It is yet another object of the present invention to provide a shower pan that prevents water leakage, and does not require sealant. 
   It is yet another object of the present invention to provide an integrally molded shower pan that can be used in a variety of shower stalls. 
   These and other objectives of the present invention are achieved by providing a shower pan for mounting in a shower stall in which the shower pan includes an integrally molded piece having a base defining a drain hole therein. A sidewall extends upwardly from the base and completely surrounds the base. A lateral ledge extends outwardly from the sidewall and has an inner edge and an outer edge defining a surface therebetween for mounting a shower stall door track thereon. An outer ridge extends upwardly from the outer edge of the lateral ledge and is in spaced apart relation to the door track. The door track and an inner wall of the outer ridge define a drain area to receive and retain water which would otherwise leak from the shower stall. 
   According to a preferred embodiment of the invention, the door track is higher than the outer ridge for allowing sufficient clearance of a shower stall door mounted on said door track to open and close over said outer ridge. 
   According to another preferred embodiment of the invention, the shower pan includes an inner ridge extending upwardly from the inner edge of the lateral ledge and has a height less than the outer ridge. The inner ridge and the outer ridge define a mounting space therebetween for mounting the door track thereon. 
   According to yet another preferred embodiment of the invention, the inner ridge is adjacent to the door track. 
   According to yet another preferred embodiment of the invention, the shower pan is made of acrylic fiberglass. 
   According to yet another preferred embodiment of the invention, the shower pan is made of marble. 
   According to yet another preferred embodiment of the invention, the sidewall is inclined toward the base to direct water to the drain hole. 
   According to yet another preferred embodiment of the invention, the base is inclined toward the drain hole to direct water to the drain hole. 
   According to yet another preferred embodiment of the invention, the lateral ledge supports an upwardly extending shower stall surface wall. 
   According to yet another preferred embodiment of the invention, the shower stall surface wall is proximate to the outer ridge. 
   According to yet another preferred embodiment of the invention, the shower pan is rectangular. The sidewall has first, second, third and fourth sides, and the door track is positioned on a portion of the lateral ledge extending from the first side of the sidewall. 
   According to yet another preferred embodiment of the invention, a shower stall surface wall is positioned on a portion of the lateral ledge extending from the second, third and fourth sides of the sidewall. 
   According to yet another preferred embodiment of the invention, a waterproof wall board is positioned behind the shower stall surface and above the outer ridge. 
   An embodiment of the method of making an integrally molded shower pan according to the invention includes the steps of providing a base and forming a drain hole in the base. In addition, a sidewall is formed extending upwardly from the base and completely surrounding the base. A lateral ledge is formed extending outwardly from the sidewall and having an inner edge and an outer edge defining a surface therebetween for mounting a shower stall door track thereon. An outer ridge is formed extending upwardly from the outer edge of the lateral ledge. The door track and an inner wall of the outer ridge define a drain area to receive and retain water which would otherwise leak from the shower stall. 
   Another embodiment of the method of making an integrally molded shower pan according to the invention includes the step of forming an incline in the base toward the drain hole to direct water thereto. 
   Another embodiment of the method of making an integrally molded shower pan according to the invention includes the step of forming an incline in the sidewall in relation to the base to direct water to the drain hole. 
   An embodiment of the method of installing a shower stall door according to the invention includes the steps of providing an integrally molded shower pan having a base defining a drain hole therein, the base being inclined toward the drain hole to direct water thereto, a sidewall extending upwardly from the base and completely surrounding the base, a lateral ledge extending outwardly from the sidewall and having an inner edge and an outer edge defining a surface therebetween for mounting a shower stall door track thereon, and an outer ridge extending upwardly from the outer edge of said lateral ledge. The door track is mounted on the lateral ledge in spaced apart relation to the outer ridge, and a shower stall door is mounted on the door track. The door tack and the outer ridge define a drain area to receive and retain water which would otherwise leak from the shower stall. 
   Another embodiment of the method of installing a shower stall door according to the invention includes the step of providing an integrally molded rectangular shower pan including a sidewall having first, second, third and fourth sides. 
   Another embodiment of the method of installing a shower stall door according to the invention includes the step of mounting the door track on a portion of the lateral ledge extending from the first side of the sidewall. 
   Another embodiment of the method of installing a shower stall door according to the invention includes the step of mounting a shower stall surface wall on a portion of the lateral ledge extending from the second, third and fourth sides of the sidewall. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which: 
       FIG. 1  is a perspective view of a shower pan according to the prior art; 
       FIG. 2  is a perspective view of a shower pan according to a preferred embodiment of the invention; 
       FIG. 3  is a cross sectional view of the shower pan of  FIG. 2  shown along line  3 ; 
       FIG. 4  is a partial perspective view of the shower pan of  FIG. 2  installed in a shower stall; 
       FIG. 5  is a cross sectional view of the shower pan and shower stall of  FIG. 4  shown along lines  5 — 5 ; and 
       FIG. 6  is a partial cross sectional view of a shower pan according to another embodiment of the invention, with a shower door track shown in phantom. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE 
   Referring now specifically to the drawings, a shower pan  10  according to the prior art is illustrated in  FIG. 1 , and shown generally at reference numeral  10 . The prior art shower pan comprises a rectangular base  11  with a drain hole  12  located in the center of the base  11  for draining water out of a shower stall. A sidewall  13  extends upwardly from the base  11 , and a lateral ledge  14  extends outwardly from the top of the sidewall  13 . On three sides of the shower pan  10 , an outer wall  15  extends above the outer edge of the lateral ledge  14 . On one side of the shower pan, the outer wall  15  terminates at the outer edge of the lateral ledge  14 . 
   A shower pan according to a preferred embodiment of the present invention is illustrated in  FIG. 2 , and shown generally at reference numeral  20 . The shower pan  20  comprises a rectangular base  21  having a drain hole  22  located in the center of the base  21 . A sidewall  23  extends upwardly from the base  21 , and a lateral ledge  24  extends outwardly from the sidewall  23 . An outer wall  25  extends above the outer edge of the lateral ledge  24  on all four sides of the shower pan  20 . As shown in  FIGS. 2 and 3 , the portion of the wall  25  extending above the lateral ledge  24  forms an outer ridge  25 A that surrounds the entire perimeter of the lateral ledge  24  and prevents the escape of water. The outer wall  25  comprises four sides: front side  25 B, rear side  25 C, left side  25 D, and right side  25 E. 
   The entire shower pan  20  is a single integrally molded piece, preferably made of acrylic fiberglass, marble, plastic or some other suitable water resistant material. While the shower pan  20  is shown as being preferably rectangular, it can be any variety of shapes such as pentagonal, hexagonal, elliptical or circular. 
   As shown in  FIGS. 2 and 3 , the sidewall  23  is preferably inclined at an angle slightly greater than ninety degrees with respect to the base  21  in order to facilitate movement of the water into the base  21 . Similarly, the base  21  is sloped toward the drain hole  22  to move water into the drain hole  22  and out of the shower pan  20 . 
   As shown in  FIG. 4 , the shower pan  20  is installed for use in conjunction with a shower stall unit  26 . A shower door track  27  is positioned on top of the lateral ledge  24  on the front side  25 B of the outer wall  25  proximate the outer ridge  25 A. The door track receives a vertical U-shaped member  33  at one end of the door track  27 . A shower stall surface wall  34  is mounted on the lateral ledge  24  on rear side  25 C, left side  25 D and right side  25 E. The shower stall surface wall  34  is positioned in front of the outer ridge  25 A. A waterproof wall board  35  is positioned behind the shower stall surface  34 , and construction studs  36  are mounted on a floor “F” behind the wall board  35 . The wall board  35  is positioned above outer ridge  25 A. The U-shaped member  33  is attached to the shower surface wall  34  positioned on the right side  25 E. The door track  27  receives a like U-shaped member at the opposite end of the door track  27  (not shown), which is attached to the shower surface wall  34  positioned on the left side  25 D. As such, the door track  27  remains in place on the shower pan  20 , without any adhesive, nor is any sealant needed to prevent leakage due to outer ridge  25 A, as described below. Alternatively, the door track  27  can be affixed to the lateral ledge  24  by any water resistant adhesive. 
   The door track  27  should be higher than the outer ridge  25 A so that the door track  27  can receive a shower door  28  without being obstructed by the outer ridge  25 A. Preferably, the door track  27  is not adjacent to the outer ridge  25 A, but rather spaced apart so that a small channel “C” exists between the door track  27  and the outer ridge  25 A, as shown in FIG.  5 . As such, water streaming down the door track  27  is caught within the channel C and ultimately flows down into the base  21  or evaporates. No sealant is necessary between the door track  27  and the shower pan  20 , since water that escapes through the door track  27  will flow into channel C and be prevented from exiting the shower pan by the outer ridge  25 A, flowing instead under the door track  27  over lateral ledge  24  and into the base  21 . In addition, outer ridge  25 A prevents water flowing between the shower stall surface wall  34  and the wall board  35  from escaping out of the shower pan  20 . By surrounding all sides of the lateral ledge  24  with outer ridge  25 A, leakage between the shower stall surface wall  34  and the wall board  35  is contained within the shower pan  10   
   As shown in  FIG. 4 , a shower door  28  is mounted on hinges  29  carried by a U-shaped member  30  extending vertically from the door track  27 . The shower door  28  is preferably made of tempered glass or other suitable water resistant material. An additional glass wall  31  is positioned on the front side  25 B of the shower pan  20  adjacent to the shower door  28 . Glass wall  31  is mounted between two U-shaped members  32 ,  33 . As shown in  FIG. 5 , the surface area of lateral ledge  24  on the front side  25 B of shower pan  20  is substantially greater than on the other sides  25 C-E, in order to accommodate the door track  27 . In addition, the portion of outer ridge  25 A on front side  25 B is thicker than the outer ridge portion on sides  25 C-E. 
   In an alternative embodiment of the invention shown in  FIG. 6 , a shower pan  20 ′ includes an inner ridge  40  positioned on the inner edge of lateral ledge  24 ′. Lateral ledge  24 ′ extends outwardly from sidewall  23 ′, which extends upwardly from base  21 ′. The inner ridge  40  is substantially smaller than the outer ridge  25 A′. A door track  27 ′ (shown in phantom in  FIG. 6 ) is positioned on the lateral ledge  24 ′ adjacent to the inner ridge  40 . The inner ridge  40  provides additional stability to the door track  27 ′. 
   A shower pan and a method of using same is disclosed above. Various embodiments of the invention can be made without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.