Tools for customizing modular shower components
12201248 ยท 2025-01-21
Inventors
Cpc classification
International classification
Abstract
Disclosed herein are methods and tools for customizing shower panels to accommodate a variety of shapes and sizes of shower bases, where such methods and tools reduce installation steps. One exemplary method includes steps of using tools to trim a back shower panel, a first side shower panel, and a second side shower panel to conform to the contours of the top edges of a shower base. An exemplary assembly of tools used to perform described methods includes a plurality of contour gauge tools and a drain center groove. Each contour gauge tool includes a contoured edge, a slot formed through the contour gauge tool, and indicia formed on a surface of the contour gauge tool. The drain center tool includes a first groove, second groove intersecting the first groove and perpendicular to the first groove, and a tab extending upward of the top surface of the drain center tool.
Claims
1. A method of preparing and installing shower panels for a modular shower, comprising: selecting prefabricated components including a shower base, a back shower panel, a first side shower panel, and a second side shower panel, wherein: the shower base includes a first top edge, a second top edge, a third top edge, and a drain hole; the back shower panel includes a left vertical edge, a right vertical edge, a top edge, and a bottom edge; the first side shower panel includes a left vertical edge, a right vertical edge, a top edge, and a bottom edge; and the second side shower panel includes a left vertical edge, a right vertical edge, a top edge, and a bottom edge; measuring a first distance from the drain hole to the first top edge, measuring a second distance from the drain hole to the second top edge, and measuring a third distance from the drain hole to the third top edge; placing a first indicator on the first side shower panel proximate to the bottom edge of the first side shower panel corresponding with the second distance; placing a second indicator on the back shower panel proximate to the bottom edge of the back shower panel that corresponds with the first distance and the third distance; placing a third indicator on the second side shower panel proximate to the bottom edge of the second side shower panel corresponding with the second distance; aligning one of a plurality of contour gauge tools with the first indicator and trimming the bottom edge of the first side shower panel based on the contour gauge tool; aligning one of the plurality of contour gauge tools with the second indicator and trimming the bottom edge of the back shower panel based on the contour gauge tool; and aligning one of the plurality of contour gauge tools with the third indicator and trimming the bottom edge of the second side shower panel based on the contour gauge tool.
2. The method of claims 1, wherein each of the plurality of contour gauge tools includes a slot formed through the contour gauge tool, wherein the slot is used to align one of the plurality of contour gauge tools with the first indicator, align one of the plurality of contour gauge tools with the second indicator, or align one of the plurality of contour gauge tools with the third indicator.
3. The method of claim 2, wherein the steps of trimming the bottom edges of the first side shower panel, back shower panel, and second side shower panel based on one of the plurality of contour gauge tools includes using the contour gauge tool to mark a desired shape of the bottom edges and trimming along the mark.
4. The method of claim 2, wherein the steps of trimming the bottom edges of the first side shower panel, back shower panel, and second side shower panel based on one of the plurality of contour gauge tools includes reversibly securing the contour gauge tool at a position that represents a desired shape of the bottom edges and using the contour gauge tool as a guide to trim the bottom edges.
5. The method of claim 2, wherein each of the plurality of contour gauge tools includes a contoured edge, where the steps of trimming the first side shower panel, second side shower panel, and the back contoured panel based on one of the plurality of contour gauge tools includes using the contoured edge of the contour gauge tool to trim the panels.
6. The method of claim 5, wherein the placement of the slot on each of the plurality of contour gauge tools is determined by the placement of the drain hole in the shower base.
7. The method of claim 6, wherein the shape of the contoured edge of each of the plurality of contour gauge tools is determined by whether the contour gauge tool is for use with the first side shower panel, second side shower panel, or back shower panel.
8. The method of claim 5, wherein the contoured edge of each of the plurality of contour gauge tools is arranged to simulate a contour of one of the top edges of the shower base.
9. The method of claim 2, wherein the slot of each of the plurality of contour gauge tools is arranged to correlate with a location of the drain hole in the shower base.
10. The method of claim 9, wherein the slot of each of the plurality of contour gauge tools is generally centered relative to the length of the contour gauge tool if the location of the drain hole in the shower base is centered.
11. The method of claim 9, wherein the slot of each of the plurality of contour gauge tools is generally offset from center relative to the length of the contour gauge tool if the location of the drain hole in the shower base is offset.
12. The method of claim 1, wherein when the shower base, the back shower panel, the first side shower panel, and the second side shower panel are installed: the first side shower panel engages with the first top edge of the shower base; the back shower panel engages with the second top edge of the shower base; and the second side shower panel engages with the third top edge of the shower base.
13. The method of claim 1, wherein: the left vertical edge of the first side shower panel is a finished edge and the right vertical edge and the top edge of the first side shower panel are trimmed; one of the left vertical edge and the right vertical edge of the back shower panel is trimmed and the top edge of the back shower panel is trimmed; and the right vertical edge of the second shower panel is a finished edge and the left vertical edge and the top edge of the second side panel are trimmed.
14. The method of claim 13, wherein: the trimming of the right vertical edge of the first side shower panel is based on the first indicator; the trimming of the left vertical edge or right vertical edge of the back shower panel is based on the second indicator; and the trimming of the left vertical edge of the second side shower panel is based on the third indicator.
15. The method of claim 13, wherein: the bottom edge of the first side shower panel is trimmed prior to the trimming of the right vertical edge of the first side shower panel; the bottom edge of the back shower panel is trimmed prior to the trimming of the left vertical edge or right vertical edge of the back shower panel; and the bottom edge of the second side shower panel is trimmed prior to the trimming of the left vertical edge of the second side shower panel.
16. The method of claim 1, wherein: the right vertical edge of the first side shower panel is a finished edge and the left vertical edge of the first side shower panel are trimmed; one of the right vertical edge and the left vertical edge of the back shower panel is trimmed and the top edge of the back shower panel is trimmed; and the left vertical edge of the second shower panel is a finished edge and the right vertical edge of the second side panel are trimmed.
17. The method of claim 1, wherein the measuring of the first distance, the second distance, and third distance is facilitated by a drain center tool.
18. The method of claim 17, wherein the drain center tool includes: a first groove; a second groove intersecting the first groove and perpendicular to the first groove; and at least one tab extending upward of the top surface of the drain center tool.
19. The method of claim 18, wherein the step of measuring of the first distance, the second distance, and third distance facilitated by a drain center tool includes: placing the drain center tool in the drain hole; orienting the drain center tool in the drain hole; placing a hook of a tape measure in the first or second groove of the drain center tool; extending the tape measure to one of the first, second, or third top edge of the shower base; and noting the distance from the drain center tool to the first, second or third top edge of the shower base.
20. The method of claim 19, wherein the step of orienting the drain center tool in the drain hole includes: arranging the drain center tool such that the first groove is generally perpendicular to the first and third top edges of the shower base; and arranging the drain center tool such that the second groove is generally perpendicular to the second top edge of the shower base.
21. The method of claim 18, wherein the least one tab is arranged to provide for manual manipulation of the drain center tool.
22. The method of claim 1, wherein each of the plurality of contour gauge tools includes indicia formed on a surface of the contour gauge tool that indicates the purpose of the contour gauge tool.
23. The method of claim 1, wherein the contour gauge tool selected for use from the plurality of contour gauge tools is selected based on the placement of the drain hole, and which one of the first side shower panel, the back shower panel, or the second side shower panel is to be trimmed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the accompanying drawings, structures are illustrated that, together with the detailed description provided below, describe example embodiments of the disclosed apparatus and methods. Where appropriate, like elements are identified with the same or similar reference numerals. Elements shown as a single component can be replaced with multiple components. Elements shown as multiple components can be replaced with a single component. The drawings may not be to scale. The proportion of certain elements may be exaggerated for the purpose of illustration.
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DETAILED DESCRIPTION
(28) The apparatus, arrangements, and methods disclosed in this document are described in detail by way of examples and with reference to the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatus, methods, materials, etc. can be made and may be desired for a specific application. In this disclosure, any identification of specific techniques, arrangements, method, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, method, etc. Identifications of specific details or examples are not intended to be and should not be construed as mandatory or limiting unless specifically designated as such. Selected examples of tools for use in customizing components, specifically shower panels, are hereinafter disclosed and described in detail with reference made to
(29) As will be described in detail herein, this disclosure is directed to embodiments of tools useful for customizing shower panels to accommodate the contours of a customized shower base. In particular, the tools facilitate the cutting of the bottom edges of shower panels so that such bottom edges of shower panels engage with the top edges of the shower base without any significant gaps between the shower panels and the shower base when the components are assembled into a shower.
(30) Modular shower kits can include one or more shower bases and one or more shower panels. Shower panels are relatively thin moisture resistant panels that attached to the existing walls of a home when installing a modular shower. The shower bases and shower panels can be fabricated in a few sizes, typically larger than is needed, and subsequently cut to the precise dimensions required for each specific bathroom. An exemplary modular shower 100 is illustrated in
(31) When a consumer decides to remodel a bathroom to include a modular shower, there remain a number of logistical issues. For example, it will be understood that requirements for the size and shape of a modular shower for remodeling an existing bathroom are substantially more complicated than designing a bathroom for a new home. A shower may need to be relocated and sized to accommodate other features in a remodeled bathroom, including safety features installed for consumers that require a safer environment in his or her home. For example, when remodeling a bathroom for an aging person, there is often more space allotted around a toilet for ease of use, handrails, grab bars and guardrails installed throughout the bathroom, and enlarged vanities with seating are installed to facilitate aging persons fully utilizing the bathroom and its amenities. Thus, it is often necessary to select an unconventional size and shape of a shower to accommodate space limitations and the other safety features to fully take advantage of the existing footprint of a bathroom remodeled for an aging person. Additionally, when remodeling an existing bathroom, one often does not fully know the shower requirements prior to starting the remodeling project. Remodeling can occur in any age range of homes, where any number of building materials could be present, and the existing bathroom could or could not have been built to any number of different building codes. Thus, further complicating this process when compared to designing a bathroom for a new home. Only once the existing shower is removed and an installer is able to see the condition of the existing subfloor and walls behind the existing shower, they will then fully understand the requirements of the remodeling situation and the requirements of the new shower. This further exacerbates the need for custom solutions as are often required in a bathroom remodeling situation.
(32) Disclosed herein is a set of tools that facilitate an accurate, efficient, and repeatable method for trimming shower panels to accommodate customized shower bases.
(33) In this example, the modular shower requires one back shower panel, a wet wall, and a side shower panel opposite the wet wall. Once the shower base 210 has been selected and trimmed to the appropriate size that accommodates the specific bathroom and a drain hole 255 drilled or otherwise formed through the shower base 210 to match the drain in the floor of the bathroom, the installer selects an appropriate back shower panel and two appropriate side shower panels (one that will serve as a wet wall and one that will be installed opposite the wet wall). The back shower panel is selected to best match the length (LB) of the back edge 270 of the shower base 210 (as illustrated in
(34) The installer measures the location of the drain hole 255 relative to the back 270 and side 280, 290 edges of the shower base 210 using any conventional measuring method. The drain center tool 300 can be used by the installer to facilitate such measurements. As illustrated in
(35) Once the drain center tool 300 is positioned in the drain hole 255 and rotated to the installer's preferred position and orientation, the installer can place the hook of the tape measure in the appropriate groove and extend the tape measure in order to the back edge 270 and the side edges 280, 290 and record the three measurements. The crosshair grooves 310 are sufficiently deep so that the hook of a tape measure can be captured in the groove 310 for ease and accuracy of measurements. Once the distances of the drain hole 255 to the edges 270, 280, 290 of the shower base 210 are recorded, the measurements are then used as a point of reference for accurately marking and trimming the back panel, wet wall, and side panel.
(36) The recorded measurements can be used in a variety of methods for marking and trimming the shower panels to accommodate the particular shower base. Generally, the installer uses the recorded measurements to apply a vertical mark on the wet wall, side shower panel, and back shower panel that correspond to the location of the drain hole 255 prior to the wet wall, back shower panel, and side shower panel being installed onto the shower base 210. As will be understood, the distance of the drain hole 255 to the back edge 270 of the shower base 210 is used to mark the wet wall and side shower panel, and the distance of the drain hole 255 to the side edges 280, 290 of the shower base 210 are used to mark the back shower panel. The installer optionally can only record and use one of the distances from the drain hole 255 to the side edges 280, 290. However, for accuracy and redundancy, the installer typically measures the distance to both side edges 280, 290 of the shower base 210.
(37) Once the wet wall, back shower panel, and side shower panel have been marked, the installer uses the contour gauge tool 400 to trim the bottom edge of the shower panels. As noted above, the contour gauge tool 400 includes a t-shaped slot 410. The t-shaped slot 410 is cut through the contour gauge tool 400 so that when positioned on a shower panel, the installer can see through the t-shaped slot 410. The installer places the contour gauge tool 400 onto the shower panel to be trimmed and adjusts the position of the contour gauge tool 400 until the drain location mark on the shower panel is located at the intersection of the two slots that comprise the t-shaped slot 410. Once properly positioned, the installer can either trace along the bottom edge 410 of the contour gauge tool 400 or clamp the contour gauge tool 400 to the shower panel, as depicted in
(38) In one specific embodiment of the method of using the tools described herein to trim shower panels, each shower panel includes a finished vertical edge with the other edges generally unfinished. The installer begins by installing the shower base. The installer inserts the drain center tool into the drain hole, appropriately positions and orients the drain center tool, makes measurements to three top edges of the shower base, and records such measurements. The installer then prepares the back shower panel by marking the drain hole location on the back shower panel relative to the finished edge of the back shower panel. The installer uses the contour gauge tool 400 to trim the bottom edge of the back shower panel. The installer then measures, marks, and trims the unfinished vertical edge opposite the finished edge and the top of the back shower panel. The installer then installs the back shower panel so that it interfaces with the applicable top edge of the shower base. The installer next prepares the wet wall by marking the drain hole location on the wet wall relative to the finished edge of the wet wall. The installer uses the contour gauge tool 400 to trim the bottom edge of the wet wall. The installer then measures, marks, and trims the unfinished vertical edge opposite the finished edge and the top of the wet wall. The installer then cuts appropriate holes to accommodate the showerhead and shower trim passing through the wet wall. The installer then installs the wet wall so that it interfaces with the applicable top edge of the shower base and the back shower panel. Finally the installer prepares the side shower panel by marking the drain hole location on the side shower panel relative to the finished edge of the side shower panel. The installer uses the contour gauge tool 400 to trim the bottom edge of the side shower panel. The installer then measures, marks, and trims the unfinished vertical edge opposite the finished edge and the top of the side shower panel. The installer then installs the side shower panel so that it interfaces with the applicable top edge of the shower base and the back shower panel. Once the shower base and all shower panels are installed, the modular shower is properly installed without any significant gaps between the shower base and shower panels. The use of the contour gauge tools significantly reduces the number of steps required to trace and trim all shower panels that interface with the sloped top surface of the shower base. By reducing the number of steps required to trace and trim all shower panels that interface with the sloped top surface of the shower base, this also significantly reduces the chance for error when performing these methods which are required for finishing a shower installation to the degree that it will be accepted both functionally and aesthetically by the home owner.
(39) As best illustrated in
(40) The contour gauge tool 400 includes a few additional convenient features. For example, the contour gauge tool 400 includes graduated distance markings along the bottom edge 420 so that the contour gauge tool 400 can also be used to measure distances for marking, etc. In this example, the markings are centered around the t-shaped slot 410. The contour gauge tool 400 includes an opening 430 that can be used by the installer to control the contour gauge tool 400 while positioning it on the shower panel. Additionally, the opening 430 can be used to conveniently carry around the contour gauge tool 400. Additional holes 440 can be formed in the contour gauge tool 400 to conveniently hang and store the tool 400 when not in use.
(41) As noted above, there are multiple contour gauge tools that are designed for various sizes and drain configurations for shower bases as well as whether the shower panel is a wet wall, the opposing side shower panel, or back shower panel. For example, the contour gauge tool 400 of
(42) Additionally, different contour gauge tools can be arranged for use based on the distance of the drain from an edge of the shower base.
(43) It is useful for an installer to have access to all the contour gauge tools when installing a modular shower. As illustrated in
(44) The contour gauge tools provided herein are only examples of contour gauge tools that accommodate shower bases. It will be understood that the ideas and arrangements disclosed herein can be applied to any number of contour gauge tools for various styles and sizes of shower bases.
(45) The foregoing description of examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The examples were chosen and described in order to best illustrate principles of various examples as are suited to particular uses contemplated. The scope is, of course, not limited to the examples set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art.