Abstract:
A low profile shower base includes a base, a threshold cover element and a support structure. The base has a floor with a perimeter wall extending upwardly from the floor, including a threshold wall section at the shower entrance, and with a drain hole located in a catchment area of the floor adjacent to the threshold wall section. The support structure holds the threshold cover element in position contiguous to the threshold wall section above the drain hole, the support structure including spaced elements that allow drainage of water therethrough under the threshold cover element and that allow the threshold cover element to be moved to give access to the catchment area.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The applicants hereby claim priority from previously filed U.S. provisional patent application Ser. No. 61/305,690, filed on Feb. 18, 2010, the contents of which are hereby incorporated by reference in their entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present subject matter concerns pre-fabricated shower bases and more particularly to a pre-fabricated low profile shower base for a shower enclosure. 
       BACKGROUND 
       [0003]    Conventional pre-fabricated shower bases have a drain hole that is located remote from an entrance or front, usually near the centre of a floor pan. A slope on the floor pan of a minimum of 2 degrees is required to direct water to the drain hole. To meet generally accepted North American standards, the threshold of the shower entrance has to be at least 2 inches above the top of the drain hole. However, allowance has to be made for deformation of the base, such as warping, between the drain and the threshold, or the material thickness has to be built up to provide adequate rigidity. Moreover, the drain hole should be provided with a cover that has to be sufficiently thick to meet standards for deflection resistance under load. For typical covers made of plastic material, thicknesses of ¾ inch or more above the drain are common. This design As a result, in practice prefabricated shower bases generally have an overall threshold height considerably more than 2 inches, typically at least 3 inches and often considerably higher. 
         [0004]    Many consumers, however, wish to have a shower enclosure with a floor pan that is approximately level with the surrounding finished floor of the room in which the shower enclosure is located, and with as low an entrance threshold as possible. The height of the entrance threshold is particularly a concern for people with disabilities or mobility constraints. In North America, there are specific standards for such installations that permit a much lower threshold than usual, but only if the floor of the room where the shower enclosure is located is equipped with another drain to capture water that may splash out of the shower enclosure. 
         [0005]    Thus there is a need for a low profile shower base. 
       BRIEF SUMMARY 
       [0006]    Accordingly in one aspect, there is provided a low profile shower base, comprising:
       a) a base having a floor with a perimeter wall extending upwardly from the floor, including a threshold wall section at the shower entrance, and with a drain hole located in a catchment area of the floor adjacent to the threshold wall section;   b) a threshold cover element; and   c) a support structure for holding the threshold cover element in position contiguous to the threshold wall section above the drain hole, the support structure including spaced apart elements that allow drainage of water therethrough under the threshold cover element and that allow the threshold cover element to be moved to give access to the catchment area.       
 
         [0010]    In one example, the shower entrance is located at the front of the base. 
         [0011]    In another example, the floor is generally rectangular. 
         [0012]    In another example, the support structure is integral with the base. The support structure includes a ledge extending along the threshold wall section upon which the threshold cover element can rest. The support structure includes a line of supports extending upwardly from the floor and separated by passages. The supports have shoulders upon which the threshold cover element can rest. The supports demarcate a transition between the floor pan area and the catchment area of the floor. The support structure includes at least one support member extending downwardly from the threshold cover element. 
         [0013]    In one example, the threshold cover element includes a plurality of openings. The plurality of openings are discrete holes or substantially parallel elongate openings. The threshold cover element is a grate. 
         [0014]    In another example, the threshold cover element is a plate. 
         [0015]    In another aspect, a ramp element extending outwardly from the threshold wall section; and a platform insert adapted to rest upon the floor of the base behind the threshold cover element providing a generally level upper surface and providing the drainage of water there through. 
         [0016]    In one example, the drain hole has a cover and the top of the threshold cover element is approximately 2 inches above the cover of the drain hole. 
         [0017]    In another example, the overall height of the base is approximately 2-¼ inches. 
         [0018]    In another example, the bottom slopes downwardly in a floor pan area toward the threshold wall section. 
         [0019]    In another aspect, a shower enclosure installation, comprising a low profile shower base, as described above, installed directly on a support structure for a finished floor. 
         [0020]    In one example, the support structure is floor joists. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    In order that the claimed subject matter may be more fully understood, reference will be made to the accompanying drawings, in which like reference numbers are employed to designate similar features, and in which: 
           [0022]      FIG. 1  is a front perspective view of a low profile shower base; 
           [0023]      FIG. 2  is an exploded front perspective view of the shower base of  FIG. 1 ; 
           [0024]      FIG. 3  is an exploded rear perspective view of the shower base of  FIG. 1 ; 
           [0025]      FIG. 4  is an exploded rear perspective view of a shower base showing an alternative design of a low profile shower base; 
           [0026]      FIG. 5  is a cross sectional view taken along line  5 - 5 ′ of  FIG. 1 ; 
           [0027]      FIG. 6  is a perspective view of an alternative threshold cover element; 
           [0028]      FIG. 7  is a perspective view of another alternative threshold cover element; 
           [0029]      FIG. 8  is a front perspective view of an alternative low profile shower base; 
           [0030]      FIG. 9  is an exploded view of the shower base of FIG.  6 ;; 
           [0031]      FIG. 10  is a perspective view of a shower enclosure with an integral shower base; 
           [0032]      FIG. 11  is an exploded view of an alternative design of a low profile shower base;; 
           [0033]      FIG. 12  is a perspective view of a floor and subfloor showing an opening to receive a low profile shower base; 
           [0034]      FIG. 13  is a perspective view of an installed low profile shower base; and 
           [0035]      FIG. 14  is a perspective view of an installed alternative low profile shower base. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    In the following description, specific details are set out to provide examples of the claimed subject matter. However, no embodiment described below is intended to define or limit the claimed subject matter. It should be apparent to those skilled in the art that many variations of the provided examples may be possible within the scope of the claimed subject matter. 
         [0037]    Referring now to  FIGS. 1 ,  2  and  3 , a low profile shower base is shown generally at  10  and comprises a base  21  with a rectangular bottom floor  22 , which defines a floor pan area  35  and a water catchment area  36 . A front wall  23 , a rear wall  25  and left and right side walls  24  extend upwardly from the floor  22  and form a perimeter. The front wall  23  includes an inward projection  26  which includes a ledge  27 . 
         [0038]    As best seen in  FIG. 3 , a line of spaced apart supports  28  extend upwardly from the floor  22  parallel to the front wall  23  demarcating a transition between the floor pan area  35  and the catchment area  36 . The supports  28  are separated by passages  29 . Each support  28  is stepped to provide a shoulder  30  facing toward the front wall  23 . The height of the shoulders  30  is approximately the same as that of the ledge  27  of the front wall  23 . 
         [0039]    Still referring to  FIG. 3 , a drain hole  39  is located in the floor  22  near the center of the catchment area  36 , between the front wall  23  and the line of spaced apart supports  28 . The floor  22  is sloped downwardly in the floor pan area  35  away from the rear wall  25  to the line of supports  28 . The floor  22  is generally level in the catchment area  36  between the front wall  23  and the line of supports  28 . A grate  31  is removably positioned over the catchment area  36  and when in place rests upon the ledge  27  of the front wall  23  and upon the shoulders  30  of the line of supports  28 . The grate  31  establishes a threshold cover element that hides the drain hole  39  from view. The grate  31  may be removed from the base  21  so that the catchment area  36  can be cleaned. The drain hole  39  may additionally include a perforated drain cover (not shown) to prevent loss of objects down the drain while allowing drainage of water. 
         [0040]    When the shower base  20  is in use, water will collect on the base  21  and travels down the slope of the floor  22  in the floor pan area  35 , through the passages  29  that separate the supports  28 , and under the grate  31  into the catchment area  36  and then down the drain hole  39 . The base  10  may be used with pre-fabricated wall panels or tiled walls known to a person skilled in the art. The shower enclosure may also include either a curtain or a door to prevent water from escaping while the shower is in use. The walls  23 ,  24 ,  25  and the bottom  22  may have an integral surface pattern, and may also be adapted for covering with tiles. 
         [0041]    It will also be appreciated that because the drain hole  39  is located behind the front wall  23  and under the grate  31 , the base  21  can be made to closer tolerances and minimal material thickness to meet the minimum depth of 2 inches between the top of the drain and the threshold, compared to conventional shower bases where the drain is located remote from the threshold and where allowance must be made for warping or other deformation or where the material must be made substantially thicker to provide sufficient rigidity. In certain examples, the maximum height of the entire base  21  can be as little as 2- 1/4  inches, assuming a material thickness of ¼ inch. 
         [0042]    The base  21  and the grate  31  may be made of extruded plastic, other synthetic polymers, such as polyvinyl chloride, acrylonitrile-butadiene-styrene, tripolymer, acrylic, polyurethane, fiberglass with gel coat, cast polymer, stainless steel, painted galvanized steel or aluminum, among other materials that are known to those skilled in the art. 
         [0043]    Referring now to  FIG. 4 , a plate  32  can be used as a threshold cover element in place of the grate  31 . The plate  32  is an inverted channel with downward flanges to provide support and rigidity with less material thickness. It will though of course be appreciated that other configurations could be used for the plate  32 , including a solid plank or an inverted pan with reinforcements webs, including a reinforcement web grid. The plate  32  also can be adapted to permit overflow water to drain in the event that drainage through the passages  28  is blocked, for example by providing for a gap around the plate  32  and the surrounding base structure. 
         [0044]    As best seen in  FIG. 5 , the front wall  23  may be extended outwardly to provide a sill  50  that can form a seal with a mounted door  51  of a shower enclosure. 
         [0045]    Referring now to  FIGS. 6 and 7 , two alternative threshold cover elements, respectively  31   a  and  31   b  are shown, which include a plurality of openings to permit water to flow downwardly through the threshold cover elements  31   a  and  31   b  and into the catchment area  36  located below. The threshold cover element  31   a  is a grate which includes a plurality of substantially parallel elongate openings  46  which extend across the length of the threshold cover element  31   a.  Alternatively, the threshold cover element  31   b  includes a plurality of discrete holes  48 . 
         [0046]    Referring now to  FIGS. 8 and 9 , an alternative design of a low profile shower base is shown generally at  100  and is intended for shower enclosures used by people with disabilities or mobility constraints. The shower base  100  includes a flooring insert  40  that rests on the floor  22  covering the floor pan area  35 , and a ramp  41  that extends outwardly from the front wall  23 . The insert  40  has a rectangular platform  42  which is supported by a plurality of flanges  43  that depend downwardly from the front, rear and side edges of the platform  42 . The front flange  43   a  includes spaced apart gaps  44  that align with the passages  29  that separate the supports  28 . The side flanges  43   b  are tapered to match the slope of the bottom  22  in the floor pan area  35  so that the platform  42  is generally level. The platform  42  also includes a plurality of drainage holes  45 . 
         [0047]    As best seen in  FIG. 10 , the side walls  24  and rear wall  25  extend upwardly as an integral one piece shower stall. 
         [0048]    Referring to  FIG. 11 , a support structure for the plate  32   a  is integral with the plate  32   a,  rather than being integral with the base  21 . The plate  32   a  is configured as an inverted channel with downward flanges to provide support and rigidity; like that described above in  FIG. 4 , however, a downwardly depending flange  52  on the side that is farthest from the front wall  23  is extended to support the threshold cover element  32   a  directly on the floor  22  of the base  21 . The flange  52  includes a plurality of spaced apart leg elements  53  with gaps  54  between them that allow drainage of water in a manner analogous to the supports  28  and passages  29  described above.. 
         [0049]    The present shower base can be used for regular shower enclosures and for shower enclosures intended for use by persons with disabilities or who have mobility constraints. As noted above, in certain examples, the total maximum height of the present shower base  21  can be as little as 2-¼ inches, assuming a material thickness of ¼ inch. In other words, if the shower base  21  is installed over a finished floor, the threshold of the resulting shower enclosure would be merely 2-¼ inches above the floor of the surrounding room. However, it should be noted that the present shower base can be supported directly on joists or similar floor support structures. 
         [0050]    As shown in  FIGS. 12 ,  13  and  14 , an appropriate opening  56  to accommodate the shower base  21  or  100  is made in the finished floor and sub-floor  58 . The shower base can then be inserted into the opening  56  resting on the underlying joists  60 . The resulting shower enclosure can have a threshold less than 1 inch above the surrounding finished floor of the room in which the shower enclosure is located. It will be noted that in such an installation for a shower enclosure intended for use by persons having disabilities or mobility constraints that the ramp  41  can be made shallower. 
         [0051]    It will of course be appreciated by those skilled in the art that many variations are possible within the scope of the claimed subject matter. The embodiments that have been described above are intended to be illustrative of the claimed subject matter and not defining or limiting. For example, while the above embodiments include a shower fixture base whose bottom is generally rectangular, numerous other rectilinear or curvilinear shapes could be used. Moreover, the shower may have its entrance at a location other than at the front, such as at a side, and may have more than one entrance, and more than one drain hole.