Patent Publication Number: US-7213274-B2

Title: Assembly for mounting shower or bath insert, insert assembly, and method of mounting insert assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of U.S. Provisional Patent Application No. 60/554,828, filed Mar. 19, 2004, the entirety of which is incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention is directed to shower and bath inserts. More particularly, the present invention is directed to an assembly for mounting shower and bath inserts in existing showers and baths, and methods for such mounting. 
   BACKGROUND OF THE INVENTION 
   There is a continuous need for materials and methods which simplify home improvement projects of all types, and which improve the results of such projects. One area of home improvement that tends to be fairly complicated, due to limits on space, the large size of the completed structure and the need to accommodate incoming and draining water, is the upgrading of baths and showers. 
   There have been a variety of products offered to simplify installation and/or improve integrity of upgraded showers and baths. Such products generally involve materials to be used to substantially replace all or part of existing showers and baths, or materials to be applied to or combined with existing showers and baths (e.g., “shower inserts” or “bath inserts”, which are generally mounted on and combined with existing structures). 
   By avoiding the need to remove all or large parts of existing showers and baths, a significant amount of labor can be avoided. In addition, parts of the existing showers and baths can provide support for inserts, and/or parts of the elements which cooperate with the existing showers and baths (e.g., drain structures, etc.) can be re-used for the inserts. 
   However, the mounting of inserts on existing structures is still time consuming, and there are frequently problems with the integrity of the finished product (e.g., leakage from connections between the existing drain and the new drain on the insert). In addition, in many instances, holes are drilled in the insert during installation, thereby detracting from the integrity and wholeness of the insert, and typically further increasing the risk for, or the extent of, water leakage. 
   There is, accordingly, an ongoing need for assemblies for mounting shower and bath inserts in existing showers and baths, which are effective to simplify the mounting of such inserts, and which result in a finished structure which has improved integrity. There is also an ongoing need for methods of mounting shower and bath inserts which are simpler and which result in a finished structure which has improved integrity. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention provides assemblies (and methods of mounting them) which simplify the mounting of shower and bath inserts in existing showers and baths, and which provide improved integrity in the completed structure. The assemblies of the present invention enable installation of inserts without the need to drill holes in or otherwise alter the insert structure. 
   In one aspect of the present invention, there is provided an insert assembly for mounting in a shower or bath. The insert assembly of the present invention comprises a retaining ring, a drain plug and an insert. 
   The retaining ring comprises an engaging structure and a retaining flange, the engaging structure and the retaining flange being integral with each other. The engaging structure has an internal surface defining a retaining ring opening which extends through the retaining ring, the internal surface having retaining ring threads formed thereon. 
   The drain plug comprises a connecting structure and a holding flange, the connecting structure and the holding flange being integral with each other. The connecting structure has an inside surface and an outside surface, the inside surface defining a drain plug opening which extends through the drain plug, the outside surface having drain plug threads formed thereon. The drain plug threads on the outside surface of the connecting structure engage the retaining ring threads on the internal surface of the engaging structure. 
   The insert is preferably selected from the group consisting of a shower insert and a bath insert. The insert has an insert opening, and the connecting structure of the drain plug extends at least partially into the insert opening. A portion of the insert is sandwiched between the holding flange of the drain plug and the retaining flange of the retaining ring. 
   Preferably, in this aspect of the invention, the retaining flange has a first retaining flange major surface and a second retaining flange major surface, and the retaining ring opening extends through the retaining ring and has a retaining ring opening axis which is substantially perpendicular to the first retaining flange major surface and the second retaining flange major surface. In addition, preferably, the holding flange of the drain plug has a first holding flange major surface and a second holding flange major surface, the drain plug opening extends through the drain plug and has a drain plug opening axis which is substantially parallel to (preferably co-linear with) the retaining ring opening axis, and the first holding flange major surface and the second holding flange major surface are substantially parallel to the first retaining flange major surface and the second retaining flange major surface. 
   According to a second aspect of the present invention, there is provided a drain assembly for mounting an insert in a shower or bath, the drain assembly comprising a retaining ring, a drain plug and a base. 
   The retaining ring comprises an engaging structure and a retaining flange, the engaging structure and the retaining flange being integral with each other. The engaging structure has an internal surface defining a retaining ring opening which extends through the retaining ring, the internal surface having retaining ring threads formed thereon. 
   The drain plug comprises a connecting structure and a holding flange, the connecting structure and the holding flange being integral with each other. The connecting structure has an inside surface and an outside surface, the inside surface defining a drain plug opening which extends through the drain plug, the outside surface having drain plug threads formed thereon. The drain plug threads on the outside surface of the connecting structure engage the retaining ring threads on the internal surface of the engaging structure. 
   The base comprises a drain structure, the engaging structure of the retaining ring extending at least partially into the drain structure, and the retaining ring being secured to the base. 
   Preferably, in the second aspect of the invention, the retaining ring is secured to the base by at least one attachment means which extends through a hole in the retaining flange and into the base. 
   Preferably, in the second aspect of the invention, the retaining flange of the retaining ring has a first retaining flange major surface and a second retaining flange major surface, the retaining ring opening extending through the retaining ring having a retaining ring opening axis which is substantially perpendicular to the first retaining flange major surface and the second retaining flange major surface. In addition, preferably, the holding flange of the drain plug has a first holding flange major surface and a second holding flange major surface, the drain plug opening extending through the drain plug having a drain plug opening axis which is substantially parallel to (preferably co-linear with) the retaining ring opening axis, and the first holding flange major surface and the second holding flange major surface are substantially parallel to the first retaining flange major surface and the second retaining flange major surface. 
   In accordance with the present invention, there is also provided a method of mounting an insert assembly in a shower or bath. The method comprises positioning a retaining ring in a drain structure, the drain structure being located in a base, the retaining ring comprising an engaging structure and a retaining flange, the engaging structure and the retaining flange being integral with each other, the engaging structure having an internal surface defining a retaining ring opening which extends through the retaining ring, and the internal surface having retaining ring threads formed thereon. 
   The method also comprises then positioning an insert above the retaining ring, the insert having an insert opening, a portion of the insert being positioned above at least a portion of the retaining flange, the insert being selected from the group consisting of a shower insert and a bath insert. 
   The method also comprises then positioning a drain plug comprising a connecting structure and a holding flange with at least a portion of the holding flange above at least a portion of the retaining flange, the connecting structure and the holding flange being integral with each other, the connecting structure having an inside surface and an outside surface, the inside surface defining a drain plug opening which extends through the drain plug, the outside surface having drain plug threads formed thereon. 
   The method also comprises then turning the drain plug to thread the drain plug threads on the retaining ring threads, whereby the connecting structure of the drain plug extends at least partially into the insert opening, and a portion of the insert is sandwiched between the holding flange of the drain plug and the retaining flange of the retaining ring. 
   Preferably, the method further comprises positioning a connecting means through an aperture in the retaining flange and into a gasket (the gasket being positioned between the drain structure and the retaining ring) after positioning the retaining ring in the drain structure, thereby securing the retaining ring to the gasket. 
   Preferably, the method further comprises positioning an attachment means through a hole in the retaining flange and into the base after positioning the retaining ring in the drain structure, thereby securing the retaining ring to the base. 
   The invention may be more fully understood with reference to the accompanying drawings and the following detailed description of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       FIG. 1  is an exploded sectional view of an insert assembly in accordance with the present invention, together with a base. 
       FIG. 2  is a perspective view of an insert assembly in accordance with the present invention. 
       FIG. 3  is a perspective view of an example of a suitable shower insert. 
       FIG. 4  is a perspective view of an example of a suitable bath insert. 
       FIG. 5  is a top view of a drain plug in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   As described above, in a first aspect of the present invention, there is provided an insert assembly for mounting in a shower or bath, the insert assembly comprising a retaining ring, a drain plug and an insert. 
   As noted above, the retaining ring comprises an engaging structure and a retaining flange, the engaging structure and the retaining flange being integral with each other, the engaging structure having an internal surface defining a retaining ring opening which extends through the retaining ring, the internal surface having retaining ring threads formed thereon. 
   As noted above, the drain plug comprises a connecting structure and a holding flange, the connecting structure and the holding flange being integral with each other, the connecting structure having an inside surface and an outside surface, the inside surface defining a drain plug opening which extends through the drain plug, the outside surface having drain plug threads formed thereon, and the drain plug threads on the outside surface of the connecting structure engage the retaining ring threads on the internal surface of the engaging structure. 
   The retaining ring and the drain plug can respectively be made of any suitable material or combination of materials. Preferably, the retaining ring and the drain plug are each made of a material or materials which render them resistant to deflection and degradation. Preferably, the portions of the retaining ring and the drain plug which, in use, contact water are substantially waterproof, i.e., they are made of a material or materials which do not readily absorb water and which do not allow significant amounts of water to pass therethrough. Persons of skill in the art are familiar with a wide variety of materials which can provide the functions desired for the retaining ring and the drain plug. For instance, examples of suitable materials for use in making suitable retaining rings and drain plugs include any non-corrosible and rigid material, including but not limited to stainless steel, plastic, copper, aluminum, etc. 
   The insert is preferably either a shower insert or a bath insert. The insert can, however, alternatively be any other type of insert. The insert has an insert opening, the connecting structure of the drain plug extending at least partially into the insert opening, a portion of the insert being sandwiched between the holding flange of the drain plug and the retaining flange of the retaining ring. Preferably, the holding flange and the retaining flange each exert a force on the insert, i.e., the insert is pressure-sandwiched between the holding flange and the retaining flange. 
   The insert can be made of any suitable material or combination of materials. Preferably, the insert is made of a material or materials which render it resistant to substantial deflection and degradation. Preferably, the insert is made of a material which is conducive to molding the insert to the desired shape. Preferably, the surfaces of the insert which, in use, contact water are substantially waterproof, i.e., they are made of a material (or materials) which do not readily absorb water and which do not allow significant amounts of water to pass therethrough. Persons of skill in the art are familiar with a wide variety of materials which can provide the functions desired for the insert, and a wide variety of inserts have been constructed and are well known to those of skill in the art. For instance, several examples of suitable materials for use in making a suitable insert include any rigid moldable material, e.g., metals, fiberglass and plastics, preferably a plastic. 
   In use, the insert assembly is positioned on a base, the base comprising a drain structure, the engaging structure of the retaining ring extending at least partially into the drain structure, the retaining ring being secured to the base. The base can be any structure on which an insert is desired to be mounted, e.g., a shower or bath structure. A wide variety of such structures exist and are well known in the art. Such structures are made of a wide variety of materials, e.g., ceramics, plastic, metal, concrete, etc. 
   Preferably, the retaining ring is secured to the base by at least one attachment means, the at least one attachment means preferably extending through a hole in the retaining flange and into a pre-drilled hole in the base. The attachment means can be any suitable device for attaching the retaining ring to the base, e.g., a screw, a nut and bolt combination, a nail, a rivet, etc. For instance, an example of a suitable attachment means is a concrete screw. 
   Preferably, a lower gasket is positioned between the retaining flange and the base. The lower gasket can be made of any suitable material or combination of materials. Preferably, the lower gasket is made of a material or materials which render it resilient. Preferably, the lower gasket is substantially waterproof, such that it can provide a seal between the retaining ring and the base. Persons of skill in the art are familiar with a wide variety of materials which can provide the functions desired for the lower gasket. For instance, an example of a suitable material for use in making a suitable lower gasket is neoprene. 
   Preferably, the lower gasket is secured to the retaining ring by at least one connecting means, the at least one connecting means extending through an aperture in the retaining flange and into the lower gasket. The connecting means can be any suitable device for attaching the retaining ring to the base, e.g., a screw, a nut and bolt combination, a nail, a rivet, etc. 
   Preferably, an upper gasket is positioned between the retaining flange and the portion of the insert which is sandwiched between the holding flange of the drain plug and the retaining flange of the retaining ring. The upper gasket can be made of any suitable material or combination of materials. Preferably, the upper gasket is made of a material or materials which render it resilient. Preferably, the upper gasket is substantially waterproof, such that it can provide a seal between the insert and the retaining ring. Persons of skill in the art are familiar with a wide variety of materials which can provide the functions desired for the upper gasket. For instance, an example of a suitable material for use in making a suitable upper gasket is rubber. 
   Preferably, the insert has a main portion and a depressed portion, the depressed portion surrounding the insert opening, the depressed portion having an upper surface which is lower than an upper surface of the main portion, and the holding flange of the drain plug is in contact with the upper surface of the depressed portion. In such a way, it is possible to reduce the extent to which the upper surface of the drain plug is above the upper surface of the main portion of the insert, or to make the upper surface of the drain plug flush with or lower than the upper surface of the main portion of the insert, and to facilitate water flowing into the drain plug opening. 
   As described above, in a second aspect of the present invention, there is provided a drain assembly for mounting an insert in a shower or bath, the drain assembly comprising a retaining ring, a drain plug and a base. 
   The retaining ring and the drain plug in the second aspect of the present invention are as described above in connection with the first aspect of the present invention. The base comprises a drain structure, the engaging structure of the retaining ring extends at least partially into the drain structure, and the retaining ring is secured to the base. 
   Preferably, the retaining ring is secured to the base by at least one attachment means, the at least one attachment means extending through a hole in the retaining flange and into a pre-drilled hole in the base. The attachment means can be any suitable device for attaching the retaining ring to the base, e.g., a screw, a nut and bolt combination, a nail, a rivet, etc. 
   Preferably, a lower gasket is positioned between the retaining flange and the base. Preferably, the lower gasket is secured to the retaining ring by at least one connecting means, the at least one connecting means extending through an aperture in the retaining flange and into the lower gasket. The connecting means can be any suitable device for attaching the retaining ring to the base, e.g., a screw, a nut and bolt combination, a nail, a rivet, etc. 
   Preferably, an upper gasket is positioned between the retaining flange and the holding flange. 
   As described above, the present invention is further directed to a method of mounting an insert assembly in a shower or bath, comprising: 
   positioning a retaining ring in a drain structure, the drain structure being located in a base, the retaining ring comprising an engaging structure and a retaining flange, the engaging structure and the retaining flange being integral with each other, the engaging structure having an internal surface defining a retaining ring opening which extends through the retaining ring, the internal surface having retaining ring threads formed thereon; 
   then positioning an insert above the base, the insert having an insert opening, a portion of the insert being positioned above at least a portion of the retaining flange, the insert being selected from the group consisting of a shower insert and a bath insert; 
   then positioning a drain plug comprising a connecting structure and a holding flange with at least a portion of the holding flange above at least a portion of the retaining flange, the connecting structure and the holding flange being integral with each other, the connecting structure having an inside surface and an outside surface, the inside surface defining a drain plug opening which extends through the drain plug, the outside surface having drain plug threads formed thereon; and 
   then turning the drain plug to thread the drain plug threads on the retaining ring threads; 
   whereby the connecting structure of the drain plug extends at least partially into the insert opening, and a portion of the insert is sandwiched between the holding flange of the drain plug and the retaining flange of the retaining ring. 
   Preferably, the drain plug threads are threaded on the retaining ring threads to such an extent that the insert is pressure-sandwiched between the retaining flange and the holding flange. 
   Preferably, the method further comprises removing a drain plate from the drain structure prior to positioning the retaining ring in the drain structure. 
   Preferably, the method further comprises positioning a lower gasket in the drain structure prior to positioning the retaining ring in the drain structure, whereby after positioning the retaining ring in the drain structure, the lower gasket is positioned between a surface which defines at least part of the drain structure and the retaining ring. 
   Preferably, the method further comprises positioning a connecting means through an aperture in the retaining flange and into the lower gasket after positioning the retaining ring in the drain structure, thereby securing the retaining ring to the lower gasket. 
   Preferably, the method further comprises positioning an upper gasket on the retaining flange prior to positioning the insert above the base, whereby after positioning the insert above the base, the upper gasket is positioned between the retaining flange and the insert. 
   Preferably, the method further comprises positioning an attachment means through a hole in the retaining flange and into the base after the positioning the retaining ring in the drain structure, thereby securing the retaining ring to the base. 
   Preferably, tape or other filler material can be placed on the base in order to reduce or fill any gap between the base and the insert. 
     FIG. 1  depicts an embodiment of an insert assembly in accordance with the present invention, together with a base (having a drain structure) on which the insert assembly can be mounted. 
   The insert assembly of  FIG. 1  includes a retaining ring  10 , a drain plug  11  and an insert  12 . 
   The retaining ring  10  comprises an engaging structure  13  and a retaining flange  14 , the engaging structure  13  and the retaining flange  14  being integral with each other. The engaging structure  13  has an internal surface  15  defining a retaining ring opening  16  which extends through the retaining ring  10 . The internal surface  15  has retaining ring threads  17  formed thereon. 
   The retaining flange  14  of the retaining ring  10  has a first retaining flange major surface  18  and a second retaining flange major surface  19 , the retaining ring opening  16  extending through the retaining ring having a retaining ring opening axis  20  which is substantially perpendicular to the first retaining flange major surface  18  and the second retaining flange major surface  19 . 
   The drain plug  11  comprises a connecting structure  21  and a holding flange  22 , the connecting structure  21  and the holding flange  22  being integral with each other. The holding flange  22  is positioned above the retaining flange  14 . The connecting structure  21  has an inside surface  23  and an outside surface  24 . The inside surface  23  defines a drain plug opening  25  which extends through the drain plug  11 . The outside surface  24  has drain plug threads  26  formed thereon. The drain plug threads  26  on the outside surface  24  of the connecting structure  21  engage the retaining ring threads  17  on the internal surface  15  of the engaging structure  13 . 
   The holding flange  22  of the drain plug  11  has a first holding flange major surface  27  and a second holding flange major surface  28 . The drain plug opening  25  has a drain plug opening axis  29  which is substantially parallel to (and co-linear with) the retaining ring opening axis  20 . The first holding flange major surface  27  and the second holding flange major surface  28  are substantially parallel to the first retaining flange major surface  18  and the second retaining flange major surface  19 . As described above, the insert  12  is preferably a shower insert or a bath insert, only a portion of the insert  12  being shown in  FIG. 1 .  FIG. 3  depicts an example of a suitable shower insert.  FIG. 4  depicts an example of a suitable bath insert. The insert  12  has an insert opening  30 , and the connecting structure  21  of the drain plug  11  extends at least partially into the insert opening  30 . A portion of the insert  12  is located between the holding flange  22  of the drain plug  11  and the retaining flange  14  of the retaining ring  10 , such that upon screwing the drain plug threads  26  into the retaining ring threads  17  to bring the drain plug  11  toward the retaining ring  10 , the insert  12  becomes pressure-sandwiched between the drain plug  11  and the retaining ring  10 . 
   The insert has a main portion  31  and a depressed portion  32 , the depressed portion  32  surrounding the insert opening  30 , the depressed portion  32  having an upper surface  33  which is lower than an upper surface  34  of the main portion  31 . In use, the holding flange  22  of the drain plug  11  is in contact with the upper surface  33  of the depressed portion  32 . 
   An upper gasket  35  is positioned between the retaining flange and the portion of the insert which is sandwiched between the holding flange  22  and the retaining flange  14 . 
     FIG. 1  depicts a base  36  on which the insert assembly can be mounted, the base  36  comprising a drain structure  37 . The engaging structure  13  of the retaining ring  10  extends at least partially into the drain structure  37 . The retaining ring  10  is secured to the base with concrete screws  38  which extend through holes  39  in the retaining flange  14  and into the base  36 . 
   A lower gasket  40  is positioned between the retaining flange  14  and the base  36 . The lower gasket  40  is secured to the retaining ring  10  with bolts  41  which extend through apertures  42  in the retaining flange  14  through holes in the lower gasket  40  and into engagement with a nut  43  on the opposite side of the lower gasket  40 . The lower gasket  40  is soft, so that it can conform to the shape of the underside of the retaining ring. 
     FIG. 2  is a perspective view of a retaining ring  10 , a drain plug  11 , an upper gasket  35 , a lower gasket  40 , a concrete screw  38 , a bolt  41  and a nut  43  of an insert assembly in accordance with the present invention. 
   In accordance with a further aspect of the present invention, there is preferably provided structure which assists in simplifying turning the drain plug to thread the drain plug threads into the retaining ring threads. For example, one preferred type of such structure is depicted in  FIG. 5 , which is a top view of a drain plug  11  having a cross plate  44  attached thereto in accordance with the present invention. In the drain plug  11  shown in  FIG. 5 , a cross plate  44  is provided which includes a generally annular section  45  which contacts a top surface  48  of the drain plug  11  and a diametrical cross portion  46  which extends across the drain plug opening  25 . The cross portion  46  has a slot  47  through which a tool can be inserted whereby upon cranking the tool clockwise or counter-clockwise relative to the top surface of the drain plug  11 , the drain plug threads  26  are screwed into or out of, respectively, the retaining ring threads  17 . The cross plate  44  can be attached to the drain plug  11  in any suitable manner, e.g., with an adhesive or structurally. For example, the cross plate  44  is attached to the drain plug shown in  FIG. 5  by applying adhesive to the top surface  48  of the drain plug  11  and then press-fitting the cross plate  44  onto the top surface  48  and into a raised rim  49  located at the outer periphery of the top surface  48  of the drain plug  11 . 
   The expression “substantially perpendicular,” as used herein, means forming an angle of between about 80 degrees and about 100 degrees. The expression “substantially parallel,” as used herein, means forming an angle of between about −10 degrees and about 10 degrees. 
   Any two or more structural parts of the drain assemblies and insert assemblies described above can be integrated. Any structural part or parts of the drain assemblies and insert assemblies described above can be provided in two or more parts (which are held together, if necessary). Similarly, any two or more method steps can be conducted simultaneously, and/or any method step can be conducted in a series of method steps.