Showe floor drain

Abstract

A concealed-shower drain assembly has a rigid vertical flange continuously joined in fixed orientation along one side of a rigid horizontal deck member. An opening in the horizontal deck leads to a. sealed drain box on the underside of the deck. A drain pipe at the bottom of the drain box provides egress of waste shower water from the drain box. A removable access panel is supported in the deck opening by a plurality of support posts affixed to the interior wall of the drain box. A continuous gap between the periphery of the access panel and the sides of the opening in the horizontal deck provides a flow path for shower waste water into the drain box. The drain assembly can be securely attached in place in a shower stall by nailing or screwing the rigid vertical flange directly to the framing of the shower stall.

Claims

1. A shower floor drain comprising: A horizontal rigid deck member having first and second parallel sides and third and four parallel sides; an opening in said horizontal rigid deck member extending from a top surface of said deck member to a bottom surface of said deck member; a drain box positioned beneath said opening in said deck member, said drain box having a closed wall extending downwardly from said bottom surface of said deck member; said drain box further comprising a drain box bottom continuously connected to the bottom of said closed wall; a downwardly directed drain pipe attached to said drain box bottom; an opening in said drain box bottom leading from said drain box bottom to an open upper portion of said drain pipe; a rigid vertical flange member continuously attached to said first side of said deck member and extending upwardly from said top surface of said deck member; said opening in said deck member having first and second opening sides, said first and second opening sides being parallel to each other, and said first and second opening sides being parallel to said first and second deck sides; a removable rigid access panel, said access panel having a first panel thickness measured between an upper surface of said access panel and a bottom surface of said access panel; a plurality of support posts; each of said plurality of support posts being attached to an interior surface of said closed wall; each of said plurality of support posts having an upwardly facing first horizontal post surface adapted to removably engage said bottom surface of access panel, said upwardly facing first horizontal post surface being vertically positioned below said top surface of said deck member a distance equal to said first panel thickness; each of said plurality of support posts further having an upper post portion extending above said upwardly facing first horizontal post surface, and said upper post portion being attached to an interior surface of said closed wall, and said upper post portion having a first post thickness and said upper post portion extending horizontally away from said closed wall into said opening in said horizontal rigid deck member a distance equal to said first post thickness; and, wherein a first pair of said plurality of support posts are disposed on opposite sides of said opening in said horizontal rigid deck member.

Description

DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a side elevation view of a linear drain embodiment of the present invention;

[0024] FIG. 2 is a plan view of the linear drain device shown in FIG. 1;

[0025] FIG. 3 is a side elevation view of a corner drain embodiment of the present invention;

[0026] FIG. 4 is a plan view of the corner drain device shown in FIG. 3;

[0027] FIG. 5 is a front elevation view of a wall drain embodiment of the present invention;

[0028] FIG. 6 is a side elevation view of a wall drain embodiment of the present invention;

[0029] FIG. 7 is a side elevation of an access panel used in conjunction with the wall drain embodiment of the present invention;

[0030] FIG. 8 is a perspective view showing the top and front of a wall drain embodiment of the present invention with the access panel removed;

[0031] FIG. 9 is a perspective view showing the bottom an front of a wall drain embodiment of the present invention with the access panel removed;

[0032] FIG. 10 is a perspective view showing the top and front of a wall drain embodiment of the present invention with the access panel in place;

[0033] FIG. 11 is a perspective view showing the bottom of a corner drain embodiment of the present invention;

[0034] FIG. 12 s a perspective view showing the top of a corner drain embodiment of the present invention with the access panel removed;

[0035] FIG. 13 is a perspective view showing the top of a corner drain embodiment of the present inventon with the access panel in place.

[0036] FIG. 14 is a cross-sectional view showing a preferred method of installation of a drain assembly constructed in accordance with the present invention.

REFERENCE NUMERALS IN DRAWINGS

[0037] B Cement Backer Board [0038] C Tile [0039] D Dimension (of Gap 7) [0040] F Shower Floor [0041] S Silicone Sealant [0042] T Thickness (of access panel 6) [0043] W Shower Wall [0044] 1 Linear Drain Assembly [0045] 2 Vertical Flange [0046] 3 Horizontal Deck [0047] 4 Drain pipe [0048] 5 Drainage box [0049] 5a Drainage box Wall [0050] 6 Access panel [0051] 7 Gap [0052] 8 Corner support post [0053] 9 Intermediate support post [0054] 10 Drain opening [0055] 11 Drain box floor [0056] 12 Drain outlet [0057] 13 Top, support post [0058] 14 Shoulder, support post [0059] 15 Strainer [0060] 16 Guide member, panel [0061] 17 Deck corner [0062] 18 fastener hole, flange [0063] 19 Fastener hole, deck [0064] 20 Fastener [0065] 30 Corner Drain Assembly [0066] 32 Vertical flange, corner drain assembly [0067] 33 Horizontal Deck, corner drain assembly [0068] 36 Access Panel, corner drain assembly [0069] 39 Drain Opening, corner drain assembly [0070] 40 Wall Drain Assembly [0071] 42 Vertical flange, wall drain assembly [0072] 43 Horizontal Deck, wall drain assembly [0073] 46 Access Panel, wall drain assembly [0074] 48 Support tab, wall drain assembly [0075] 49 Drain Opening, wall drain assembly

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0076] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

[0077] Referring now to FIGS. 1 and 2, there is shown a front and top view, respectively, of a linear drain assembly, generally designated 1 in the drawings.

[0078] In the preferred embodiment of the present invention, the linear drain assembly 1 comprises a rigid horizontal deck 3 that has a drain opening 10. In the preferred embodiment of the invention both the horizontal deck 3 and the drain opening 10 are generally of a rectangular shape. The outboard corners 17 of the horizontal deck preferably are fixed radius curves, rather than sharp corners, to enhance the strength of the mud joint around the deck 3 when the device is installed in a shower floor. A drainage box 5 is disposed beneath the horizontal deck3 and has continuous walls 5a, which extend downwardly from the periphery of the drain opening 10. The drain box walls 5a are continuously connected at their bottom portion to the drain box floor 11 and at their top portion to the underside of the horizontal deck 3. A drain pipe 4 extends downwardly from an opening in the drain box floor 11. In the preferred embodiment of the invention, a portion of the drain box floor 11 is sloped so as to direct gravity flow of waste shower water out of the drain box 5 through the drain pipe 4 when the assembly is in operation.

[0079] It will be understood that the drainage box walls 5a form a continuous, closed and watertight seal with the horizontal deck 3 around the periphery of the drain opening 10.

[0080] A rigid vertical flange 2 forms a fixed, continuous and watertight intersection with the horizontal deck 3 along one of its elongated sides. The vertical flange 2 and the horizontal deck 3 form an “L” in cross section along the entire length of one long side of the horizontal deck 3.

[0081] The drainage box 5, the vertical flange 2, the horizontal deck 3 and the drain pipe 4 together form a unitized rigid structure. In the preferred embodiment of the invention, the drainage box 5, the vertical flange 2, the horizontal deck 3 and the drain pipe 4 are all constructed as a single molded plastic part.

[0082] A panel corner support post 8 is attached to the drainage box wall 5a in each corner of the drainage box 5. Each panel corner support post 8 has a substantially horizontal support post shoulder 14 that is recessed below the upper surface of the horizontal deck 3.

[0083] A rigid access panel 6 removably rests on the shoulder 14 of the panel corner supports posts 8.

[0084] In the preferred embodiment of the invention, a panel guide member 16 is disposed in each corner of the drainage box 5. Each panel guide member 16 preferably protrudes a finite distance (D) from the two intersecting walls 5a that form each vertical corner of the drainage box 5. In the preferred embodiment of the invention, the access panel is similar in shape to the (preferably rectangular) drain opening 10, but is smaller in length and width than the corresponding length and width of the drain opening, so as to provide a substantially continuous gap 7 of dimension D between the periphery of the access panel 6 and the opening 10 in the horizontal deck 3. It will be understood that, in operation, shower waste water may advantageously gravity flow from above the horizontal deck 3, through the gap 7, downwardly into the drainage box 5, and then out of the drainage box 5 via the drain pipe 4.

[0085] In the preferred embodiment of the invention one or more pairs of intermediate support posts 9 is attached intermediately on opposite sides of the drainage box wall 5a to provide additional support to the access panel 6.

[0086] In the preferred embodiment of the invention, the width and length of the access panel 6 is substantially equal to 2×D less than the width and length, respectively, of the opening 10 in the horizontal deck 3, such that access panel 6 fits between opposing guide members 16, whereby the array of panel guide members 16 prevent horizontal movement of the access panel 6 within the opening 10 in the horizontal deck 3.

[0087] By way of example only, the dimensions of a linear drain assembly 1 constructed in accordance with the preferred embodiment of the invention are as follows:

[0088] The length of the horizontal deck 3 and the vertical flange 2 is 28½″. The vertical flange 2 extends to a maximum height of 2 inches above the upper surface of the ½-inch thick horizontal deck 3. The horizontal deck 3 is 5½″ wide, as measured from the back side of the vertical flange 2. The drain opening 10 in the horizontal deck 3 is 2½ inches wide by 24½ inches long. The access panel 6 is 2 inches wide by 24 inches long, thereby providing a substantially uniform and continuous ¼-inch gap between the edge of the panel 6 and the edge of drain opening 10 in horizontal deck 3.

[0089] The intermediate support post 9 and the corner support post 8 are each ½-inch square in horizontal cross section.

[0090] Each guide member 16 protrudes approximately ¼″ from the wall 5a of the drain box 5 to provide a substantially continuous ¼-inch gap 7 between the perimeter of the access panel 6 and the edge of the drain opening 10 in the horizontal deck 3.

[0091] Installation

[0092] As will be described more fully herein below, the linear drain assembly 1 is constructed so as to be installed against a vertical wall (W) of a tiled shower stall at the shower floor (F). In operation, the linear drain assembly 1 is recessed relative to a tiled shower floor F, such that waste shower water flows from the shower floor F, through gap 7 between the horizontal deck 3 and the removable access panel 6, downwardly into the drainage box 5, then out of the drainage box through drain pipe 4.

[0093] The preferred method of installing the linear drain assembly 1 in a shower stall will now be described.

[0094] Referring to FIG. 14: The linear drain assembly 1 is initially placed in an opening in the subfloor of a roughed out shower stall. A continuous bead of silicone sealant (S) or the like is preferably applied to the shower stall subfloor, between the underside of the horizontal deck 3 and the subfloor.

[0095] The outboard face of the vertical flange 2 is securely fastened directly to the wall frame (preferably to the studs) with screw or nail fasteners 20. The vertical flange 3 may be provided with pre-drilled fastener holes 18 to facilitate screwing of the vertical flange 3 to the wall studs. The horizontal deck 3 is securely fastened directly to the subflooring with screw or nail fasteners 20. The horizontal deck 3 may be provided with pre-drilled fastener holes 19 to facilitate screwing of the horizontal deck to the subflooring. It will be understood that after the vertical flange 3 has been fastened to the wall framing, and the horizontal deck 3 has been fastened to the subflooring, the unitized rigid subassembly comprising the vertical flange 3, drainage box 5 and horizontal deck 3 will all be rigidly held in place and will not be susceptable to being displaced during completion of construction operations in the shower stall.

[0096] In the preferred embodiment of the invention, the horizontal deck 3 is ½″ thick, corresponding to the thickness of the cement board B that typically forms the base of tiled shower floor. Similarly, the vertical flange 2 is ½″ thick, corresponding to the thickness of the cement board B that typically forms the base for the tiled shower wall.

[0097] After the drain subassembly comprising the vertical flange 2, the drainage box 5 and the horizontal deck 3, has been fastened to the shower stall framing, cement board B, which has the same thickness as the vertical flange 2 and the horizontal deck 3, is then attached to all exposed interior surfaces of the roughed-out shower stall.

[0098] After the drain subassembly (comprising the vertical flange 2 the drainage box 5 and the horizontal deck 3) and the cement board B have been installed, mud and tile (C) can be applied to the exposed face of the horizontal deck 3 (as well as the remainder of the shower floor F), and to the exposed face of the vertical flange 2 (as well as the remainder of the shower wall W) in the standard manner of constructing tiled shower surfaces. It will be understood that, as the tile C and mud (not shown) extend uniformly in a plane across both the cement board and the horizontal deck 3 at the floor, and across both the vertical flange and the cement board at the wall, the described drain assembly installation is watertight at both the shower wall W and the shower floor F, and requires no additional sealing members. It will also be understood that, since the mud and tile C are applied directly over the vertical flange 2 and the horizontal deck 3, the fasteners 20 are hidden from view and fastener holes 18, 19 are sealed against water leakage.

[0099] In a similar manner by which mud and tile C are applied to the shower floor F, mud and tile C are also preferably applied to the exposed upper surface of the access panel 6.

[0100] In a preferred embodiment of the invention a hair strainer 15 is removably disposed within the drainage box 5 at the drain pipe 4. The hair strainer 15 can be easily accessed, without requiring the use of tools, by lifting the access panel 6 by hand from the support posts on which it rests.

[0101] It will be understood from the above description that the drain subassembly (comprising the vertical flange 2 the drainage box 5 and the horizontal deck 3) together form a unitized rigid structure that can advantageously he constructed, handled and installed in place in a shower stall as a single part.

[0102] It will be understood that the present invention can be installed at any point along the floor-wall intersection of the shower, including in the corner or in the middle of a wall. An alternative embodiment of the present invention comprises an elongated recessed drain that extends along the entirety of one of the edges of the shower. In this embodiment of the invention, the drain is adapted to be substantially hidden from view, providing users with all of the function of convention drains without the aesthetically unappealing appearance.

[0103] FIGS. 4 and 11-12 show a corner drain assembly, generally indicated as 30, which is a variation of the present invention that is adapted to be installed in the corner of the floor of a shower. By way of example, a preferred embodiment of the corner drain assembly 30 has a ½-inch thick horizontal deck 33 that is 9½″ by 9½″ and has a 6-inch square removable access panel 36, which fits inside of a 6½ inch square drain opening 39. The corner drain assembly 30 has two vertical flanges 32 that each extend to a height of 4 inches above the horizontal deck 33.

[0104] FIGS. 5-10 show a wall drain assembly, generally indicated as 40, which is a variation of the present invention that is adapted to be installed in the wall of a shower. By way of example, a preferred embodiment of the wall drain assembly 40 has a ½-inch thick horizontal deck 43 that is 16 inches long and 3 inches wide. The wall drain assembly 40 has a single vertical flange 42 that is 14¼ inches wide and extends to a height of 9″ above the horizontal deck 43. A 10¼ wide drain opening 49 is centered in the vertical flange 42, extending from the top of the horizontal deck 43 to a height of 7 inches. A removable 9¾″×6″ access panel 46 rests on support tabs 48 affixed to the back side of the vertical flange 42, so as to provide a ¾-inch gap between the bottom of the access panel 46 and the top of the horizontal deck 43, a ¼-inch gap between the vertical sides of the panel 46 and the vertical flange 42, and a ¼-inch gap between the top edge of the panel 46 and the vertical flange 42.

[0105] Many other modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example: [0106] The horizontal deck can be various shapes other than rectangular; [0107] The thickness of the horizontal deck and the thickness of the vertical flange can be other than ½″, but should preferably be the same thickness as the cement board or other material upon which the shower tile is to be adhered; [0108] The opening in the deck can be various shapes other than substantially rectangular; [0109] Rather than being molded of a single component, the horizontal deck, the drainage box, the support posts and the vertical flange can be rigidly welded or glued to adjacent parts of the assembly; [0110] The panel guides and the support posts may be constructed as individual components or may, alternatively, be formed from a single component; [0111] The outboard corners of the horizontal deck can have radii or may be sharp corners; [0112] The material of construction of the drain assembly can be plastic or other such rigid waterproof materials. [0113] The horizontal deck can be secured in place on a shower subfloor without the use of a silicone sealant; and, [0114] In the preferred embodiment of the invention drain pipe 4 comprises 2″ plastic pipe, but different sizes of pipe and different pipe materials can be alternatively used; [0115] In a wall drain embodiment of the invention, such as illustrated in FIGS. 5-10, the deck member and access panel are in a vertical plane, and the drainage box and drain pipe are located behind the shower wall; [0116] In a corner drain embodiment of the invention such as illustrated in FIGS. 3, 4 and 11-13, two adjacent sides of the horizontal deck plate are provided with contiguous vertical flanges that are adapted to be fastened to two adjacent shower walls.

[0117] Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.