Abstract
A shower pan is provided. The shower pan includes a body having a perimeter, a central portion internal with respect to the perimeter, a top surface, and an aperture defined by the body in the central portion operable to allow a liquid to flow therethrough, the body comprising a slope to direct a liquid to the aperture, wherein the body defines a groove along a portion of the perimeter, The groove is operable to receive a wall base substrate of a shower to engage the groove in a waterproof manner. The top surface comprises a slip resistant texture.
Claims
1. A shower pan, comprising: a body comprising a perimeter, a central portion internal with respect to the perimeter, a top surface, and an aperture defined by the body in the central portion operable to allow a liquid to flow therethrough, the body comprising a slope to direct a liquid to the aperture, wherein the body defines a groove along a portion of the perimeter, the groove operable to receive a wall base substrate of a shower to engage the groove in a waterproof manner, wherein the top surface comprises a slip resistant texture.
2. The shower pan according to claim 1, wherein the groove comprises a first surface and a second surface extending from and being disposed substantially perpendicular to the first surface, wherein the top surface extends from and is disposed substantially perpendicular to the first surface, and wherein the perimeter of the body has a third surface extending from and being disposed substantially perpendicular to the second surface.
3. The shower pan according to claim 2, wherein the shower pan is configured to receive at least one adhesive applied to the first surface, the second surface, and a portion of the top surface extending from the first surface, and operable to allow the wall base substrate of the shower to engage with the first surface and the second surface in the waterproof manner, and allow a liner of the shower to engage with the top surface of the body and the wall base substrate in the waterproof manner.
4. The shower pan according to claim 1, wherein the top surface comprises a wet dynamic coefficient of friction of 0.4 or greater.
5. The shower pan according to claim 1, wherein the slope comprises an angle with respect to a horizontal plane, and wherein the top surface further has a minimum pendulum test value of 36 or greater.
6. The shower pan according to claim 1, wherein the body comprises at least one additively formed element.
7. The shower pan according to claim 1, wherein the body comprises at least one of quartz and rock.
8. A method of fabricating a customized shower pan, comprising the steps of: providing measurements to an apparatus, the measurements comprising at least one of body dimensions and a drain position in the body; manufacturing an aperture in the body for allowing a liquid to flow therethrough; manufacturing a slope on the body with the apparatus such that the slope is configured to direct a liquid to the aperture; and applying a slip-resistant texture to a surface of the body.
9. The method according to claim 8, further comprising manufacturing a groove along at least a portion of a perimeter of the body in order to allow a wall base substrate of a shower to engage with the groove in a waterproof manner, and such that a liner of the shower engages with both a top surface of the body and the wall base substrate.
10. The method according to claim 9, wherein the groove is defined by a first surface and a second surface extending from and being disposed substantially perpendicular to the first surface, and wherein the top surface extends from and is disposed substantially perpendicular to the first surface.
11. The method according to claim 10, further comprising defining the perimeter of the body with a third surface extending from and being disposed substantially perpendicular to the second surface.
12. The method according to claim 10, further comprising applying an adhesive to the first surface, the second surface, and the portion of the top surface extending from the first surface in order to both allow the wall base substrate of the shower to engage with the groove in the waterproof manner, and allow the liner of the shower to engage with the top surface of the body and the wall base substrate.
13. The method according to claim 9, further comprising coupling a curb member to the body along a portion of the perimeter.
14. The method according to claim 8, wherein the apparatus comprises an additive manufacturing apparatus.
15. The method according to claim 8, wherein the body comprises at least one of quartz and rock.
16. The method according to claim 8, wherein the apparatus comprises a computer numerical control (CNC) apparatus.
17. The method according to claim 8, wherein manufacturing the slope on the body comprising fabricating the slope with an abrasive wheel.
18. The method according to claim 8, further comprising applying the slip-resistant texture to the body with a brush of the apparatus by rotating the brush and engaging the body with the brush while the brush is rotating.
19. The method according to claim 8, wherein the slip-resistant texture comprises a wet dynamic coefficient of friction of 0.4 or greater.
20. The method according to claim 8, wherein the slip-resistant texture comprises a finish comprising a minimum pendulum test value of 36 or greater.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1A is a top plan view of a shower pan, in accordance with one non-limiting embodiment of the disclosed concept.
[0026] FIG. 1B is a section view of the shower pan of FIG. 1A, taken along line B-B of FIG. 1A, and shown with a portion of a wall base substrate and a liner of a shower coupled to a groove of the shower pan.
[0027] FIG. 1C is an enlarged view of a portion of the shower pan of FIG. 1B, along with the portion of the wall base substrate and member of the shower.
[0028] FIG. 1D shows the portion the shower pan and portion of the wall base substrate and member of the shower of FIG. 1C, along with an adhesive.
[0029] FIG. 1E is an enlarged view of another portion of the shower pan of FIG. 1B.
[0030] FIG. 2 is a simplified view of a computer numerical control (CNC) apparatus, shown with a body that is configured to be manufactured by the CNC apparatus in order to produce the shower pan of FIGS. 1A-1E.
[0031] FIG. 3 is a flow chart corresponding to an example method of fabricating the shower pan of FIGS. 1A-1E.
DETAILED DESCRIPTION
[0032] As employed herein, the term coupled shall mean connected together either directly or via one or more intermediate parts or components.
[0033] As employed herein, the term number shall mean one or an integer greater than one (i.e., a plurality).
[0034] As employed herein, the term adhesive shall mean a substance configured to directly join a first component to a second component. Adhesives in accordance with the disclosed concept may include one or more of sealants, tapes, gels, solids and liquids, catalyzed and non-catalyzed adhesives, and/or glues.
[0035] FIG. 1A is a top plan view of a shower pan 102, in accordance with one non-limiting embodiment of the disclosed concept. The shower pan 102 is preferably made of relatively durable materials, including granite, quartz, marble, compositions comprising rock and/or minerals (e.g., quartzite, silicate minerals, oxide minerals, carbonate miners, metamorphic rock, igneous rock, phaneritic rock), composites with or without rock and/or minerals, resins and/or plastics with or without rock and/or minerals, wood, ceramics, and porcelains. Additionally, as will be discussed below, the shower pan 102 is configured to be manufactured in a customized manner that is tailored to a specific installation area, and is also configured to be installed in an installation area in a waterproof manner such that water during a shower does not leak between junctions of the shower pan 102 and wall materials (partially shown in FIGS. 1B-1D, and discussed below). In order to do this, measurements are first taken at the installation area, such as a predetermined drain position with respect to features of the installation area, such as studs, footers, construction substrates, foundation, subflooring, plumbing. The measurements are then used by an apparatus to manufacture the shower pan 102. The apparatus and process will be discussed below, after discussion of the structure of the shower pan 102. It will also be appreciated that the disclosed shower pan 102 and associated method 400 may be configured in accordance with standard industry dimensions and geometry (e.g., not customized for a specific installation area).
[0036] Continuing to refer to FIGS. 1A and 1B, the shower pan 102 includes a body 104 having a perimeter 106, a central portion 108 internal with respect to the perimeter 106, a top surface 110, and an aperture 112 (e.g., a thru hole) in the central portion 108 that is configured to allow a liquid to flow therethrough. It will be appreciated that the aperture 112 in the body 104 is configured to receive a drain (not shown) during assembly and installation of the shower pan 102 in an installation area. It will be appreciated that different drain configurations may have different sizes, dimensions, and/or geometries. For example, rectangular drains may extend substantially across the shower pan 102, and an appropriately configured aperture 112 would be present. It will also be appreciated that a shower may not include a drain, such that a shower pan in accordance with the disclosed concept may have a slope that directs liquid off a corresponding body. For example, without limitation, an installation where there is no drain and/or plumbing having a desired location to direct liquid runoff, or for an installation having a drain adjacent to the body but defined by the body.
[0037] As shown in the FIGS. 1B and 1E, the body 104 includes a slope to direct a liquid to the aperture 112, and also includes a groove 120. The groove 120 may be configured to have a single rabbet or may have multiple adjacent rabbets (not shown) in order to accommodate multiple layers of substrate in a stepped configuration. The groove is disposed along a portion of the perimeter 106 and configured to allow a wall base substrate 130 (FIGS. 1B-1D) of a shower to engage the recessed groove 120 in a waterproof manner.
[0038] The shower pan 102 may also further include a curb member 114 coupled to a portion of the perimeter 106 of the body 104, which in some embodiments allows a piece of glass and/or a door to engage therewith. In some embodiments, the curb member 114 limits liquid passage from passing thereover. In one example, the curb member 114 is coupled to the portion of the perimeter 106 via at least one adhesive 150. In some embodiments, no curb member is present, which may allow for installations where a top surface of a shower pan is at a same elevation as adjacent flooring. In some embodiments a piece of glass and/or a door to engages directly with the shower pan 102.
[0039] Additionally, as shown in FIG. 1C, the body 104 further has the recessed groove 120 along a portion of the perimeter 106 in order to allow a wall base substrate 130 (FIG. 1B) of a shower to engage with the recessed groove 120 in a waterproof manner. The top surface 110 has a textured finish. The wall base substrate 130 may comprise, without limitation, wood, drywall, greenboard, cement board, foam board, foam panels with waterproof membranes, HardieBacker, and the like.
[0040] As shown in FIG. 1C, the recessed groove 120 is provided by a first surface 122 and a second surface 124 extending from and being located substantially perpendicular to the first surface 122. Additionally, the top surface 110 extends from and is located substantially perpendicular to the first surface 122, and the perimeter 106 of the body 104 has a third surface 126 extending from and being located substantially perpendicular to the second surface 124. In this manner, the recessed groove 120 is configured to receive the wall base substrate 130 at a recessed (e.g., stepped down) position with respect to the top surface 110 of the shower pan 102, and a liner 140 of the shower is configured to engage with both the top surface 110 of the body 104 and the wall base substrate 130. It will be appreciated that the liner 140 can include, among other materials, granite, quartz, marble, compositions comprising rock and/or minerals (e.g., quartzite, silicate minerals, oxide minerals, carbonate miners, metamorphic rock, igneous rock, phaneritic rock), composites with or without rock and/or minerals, resins and/or plastics with or without rock and/or minerals, wood, tile, ceramics, and porcelains.
[0041] Referring to FIG. 1D, in order to allow for these waterproof junctions, the shower pan 102 is configured to receive at least one adhesive 152 applied to the first surface 122, the second surface 124, and a portion of the top surface 110 extending from the first surface 122. The adhesive 152 therefore allows both the wall base substrate 130 of the shower to engage with the recessed groove 120 in a waterproof manner, and the liner 140 to sealingly engage with the top surface 110 of the shower pan 102 and the wall base substrate 130.
[0042] In one example, the top surface 110 of the body 104 preferably has a wet dynamic coefficient of friction of about 0.4 or greater, more preferably being at least 0.150 (nonlimiting e.g., for interior wet areas), and in one example at least 0.55 (nonlimiting e.g., for exterior wet areas). The top surface 110 preferably has a minimum pendulum test value that is a predetermined value greater than about 30. In yet a further example embodiment of the disclosed concept, the body 104 is sloped downward from the perimeter 106 to the aperture 112 at an angle 116 with respect to a horizontal plane 118, and See, for example, the angle 116 depicted in FIG. 1E with respect to the horizontal plane 118. In this manner, the shower pan 102 is advantageously configured to provide safeguards against slipping, thus improving safety for users of the shower pan 102. In one example, the top surface 110 both has a wet dynamic coefficient of friction of about 0.4 or greater, and has a minimum pendulum test value that is about 36 or greater. Testing procedures and/or results are, in some embodiments, in accordance with industry standards, such as the American National Standards Institute (ANSI), and/or the American Society for Testing and Materials (ASTM). Other industry standards are also considered. In an embodiment the shower pan 102 top surface 110 meets or exceeds ANSI A326.3/A137.1 Dynamic Coefficient of Friction Test standards. In an embodiment the shower pan 102 top surface 110 comprises a minimum pendulum test value of 36, per American Society for Testing and Materials Method E303-22 (2022), Standard Test Method for Measuring Surface Frictional Properties Using the British Pendulum Tester.
[0043] Continuing to refer to FIG. 1E, in one example the aperture 112 is provided by a plurality of surfaces, such as first tubular surface 112A, a disc-shaped surface 112B extending from and optionally being located perpendicular to the first tubular surface 112A, and a second tubular surface 112C extending from and optionally being located perpendicular to the disc-shaped surface 112B. In this manner, the surfaces 112A, 112B, 112C provide a step-down feature of the shower pan 102 for allowing one or more drain portions (not shown) to be coupled to the body 104 within the aperture 112, which is illustrated as a disc, although other shapes are considered.
[0044] In one example, the shower pan 102 (FIGS. 1A-1E) is configured to be manufactured in a customized manner via an apparatus. In embodiment, the apparatus is a CNC apparatus 200. FIG. 2 illustrates an embodiment shown in simplified form in FIG. 2. The CNC apparatus 200 in FIG. 2 is positioned proximate a body 300, and is configured to manufacture the body 300 into the body 104 depicted in FIGS. 1A-1E. In an embodiment, the CNC apparatus 200 includes tooling 210, a 400-800 grit component 220, an abrasive wheel 230, and a brush member 240, each of which is shown in simplified form in FIG. 2. Other standard CNC apparatus 200 features are left out for clarity, but will be understood to be present by those skilled in the art. In some embodiments, the CNC apparatus may comprise one or more of a tooling, laser, surface grinder, additive manufacturing apparatus, water jet, and the like.
[0045] In accordance with the disclosed concept, a method 400 of fabricating the shower pan 102 (FIGS. 1A-1E) with an apparatus (e.g., the CNC apparatus 200) is provided in FIG. 3. The method 400 can be understood as being performed on the body 300 such that the body 300 is manufactured into the body 104 (FIGS. 1A-1E). As such, the method 400 will be described in association with the body 104, although it will be appreciated that the method 400 is performed on the body 300 in FIG. 2 in order to fabricate the body 300 into the body 104 of FIGS. 1A-1E.
[0046] In one example, the method 400 preferably includes a first step 402 of receiving measurements of an installation area or otherwise predetermined dimensions at an apparatus (e.g., the CNC apparatus 200), the measurements including a predetermined drain position and geometry, and body 300 dimensions and geometry that accommodate installation requirements. The method 400 preferably also includes a second step 404 of providing instructions (e.g., CAD, programing, g-code, or the like) to the CNC apparatus 200 or associated electronics and/or computing device, which includes, inter alia, providing the measurements such as the location of the body 104 and the drain position. A third step 406 comprises manufacturing an aperture 112 in the body 104 for allowing a liquid to flow therethrough. A fourth step 408 comprises manufacturing a slope on the body 104 with the CNC apparatus 200 such that the slope descends towards the aperture 112. In one example, the fourth step 408 of manufacturing the slope on the body 104 includes tooling the slope with the abrasive wheel 230 (FIG. 2), and optionally includes rotating the abrasive wheel 230 at a speed of between 4,500 and 6,500 revolutions per minute, and feeding the body 104 at a feed rate of between 1,000 to 2,000 millimeters per minute. In an embodiment, the abrasive wheel 230 comprises a calibrating wheel.
[0047] A fifth step 410 comprises finishing a top surface of the body 104 with the CNC apparatus 200. In one example, the fifth step 410 of finishing further includes finishing the top surface 110 with the component 220 of the CNC apparatus 200, with tooling not limited to mills, bits, grinders, and/or brushes. In other embodiments, the finish is created via chemical etching, etching tools, abrasives, and/or abrasive blasting, alone or in combination with a CNC apparatus 200.
[0048] Additionally, as discussed above, the shower pan 102 (FIGS. 1A-1E) preferably has a recessed groove 120 to allow for desired waterproof mating with the wall base substrate 130 and the liner 140. Thus, the method 400 also preferably includes a sixth step 412 of manufacturing the recessed groove 120 along at least a portion of the perimeter 106 of the body 104 and a seventh step 414 comprising engaging the wall base substrate 130 with the recessed groove 120 in a waterproof manner, and engaging the liner 140 with the body 104 and the wall base substrate 130. In order to couple the wall base substrate 130 and the liner 140 to the body 104, the method 400 preferably comprises applying the adhesive 152 to the first surface 122, the second surface 124, and the portion of the top surface 110 extending from the first surface 122 in order to both allow the wall base substrate 130 to engage with the recessed groove 120 in a waterproof manner, and allow the liner 140 to engage with the top surface 110 of the body 104 and the wall base substrate 130.
[0049] Optionally, the method 400 also includes an eighth step 416 of coupling the curb member 114 (FIGS. 1A and 1B) to the body 300 along a portion of the perimeter 106. A piece of glass, brackets, and/or a door to a shower engages therewith in some embodiments. It will be appreciated that in order to join the curb member 114 to the body 104, the method 400 may also include applying the adhesive 150 between the curb member 114 and the body 104 along a portion of the perimeter 106, and allowing the adhesive 150 to set for a predetermined period of time. Continuing to refer to FIG. 3, the method 400 also optionally includes a ninth step 418 of applying a texture finish to the body 104. In some embodiments, this comprises applying a texture finish to the body 104 with the brush member 240 (FIG. 2) of the CNC apparatus 200 by rotating the brush member 240 and engaging the body 104 with the brush member 240 while the brush member 240 is rotating. In other embodiments, forming a textured finish is accomplished by one or more oof chemical etching, abrasives, and/or abrasive blasting, alone or in combination with CNC operations.
[0050] Additionally, as mentioned above, the shower pan 102 is configured to be a customized shower pan, meaning that for a given installation area, a shower pan will be manufactured by the method 400 that accommodates the particular geometry of that particular installation area. As such, although the method 400 has been disclosed herein in association with fabricating the shower pan 102 of FIGS. 1A-1E, it will be appreciated that the method 400 preferably includes additional steps for fabricating a second shower pan different than the shower pan 102 illustrated, those additional steps including receiving second measurements of a second installation area at the CNC apparatus 200, initiating the program of the CNC apparatus 200 to determine a geometry of a second body (not shown) and a second drain position (e.g., the location of the second body with respect to a perimeter of the second body being different than the location of the body 104 with respect to the perimeter 106 of the body 104), manufacturing the location of the second body (not shown) to establish an aperture in the second body, manufacturing a slope on the second body (not shown) with the CNC apparatus 200 such that the slope descends from the perimeter of the second body (not shown) to the aperture of the second body, and brush finishing a top surface of the second body with the CNC apparatus 200. In this manner, it will be appreciated that all of the steps 402-418 of the method 400 are configured to be performed on large pluralities of different bodies in order to manufacture different customized shower pans each being tailored to fit a corresponding different installation area with different drain positions.
[0051] Moreover, in non-limiting applications of the disclosed concept, the sixth step 412 of manufacturing the recessed groove 120 further includes rotating the tooling 210 (FIG. 2) of the CNC apparatus 200 at a speed of between 4,000 and 7,400 revolutions per minute at a first feed rate for a first predetermined distance in order to form a first portion of the recessed groove 120, and a second feed rate for a second predetermined distance in order to apparatus a second portion of the recessed groove 120 after the first portion of the recessed groove 120 has been formed, and such that the first feed rate is less than the second feed rate in order to allow the tooling 210 of the CNC apparatus 200 to achieve a desired finish while manufacturing the recessed groove 120. In one example, the first feed rate is preferably between 150 and 250 millimeters per minute, and the second feed rate is preferably between 275 and 375 millimeters per minute. Additionally, in order to account for a body being made of different materials (e.g., a first piece of material in one instance and second, different piece of material in another instance), the first feed rate and the second feed rate are first amounts when the tooling 210 is manufacturing the body being made of the first piece of material and second amounts when the tooling 210 is manufacturing a body made of the second piece of material, such that the first and second amounts are different from one another and correspond to differences in the first and second pieces of material. In some embodiments, a predetermined level of tool marks accommodates the requirements of the adhesives/sealants being used for the installation process.
[0052] In embodiments, the CNC apparatus 200 may comprise an additive manufacturing apparatus using a resin and/or mineral and/or rock containing a substrate (e.g., without limitation, a 3D printing process), one or more of Fused Deposition Modeling (FDM), Stereolithography (SLA), Digital Light Processing (DLP), Selective Laster Sintering (SLS), MJF (Multi Jet Fusion), Binder Jetting, PolyJet, and/or Direct Metal Laser Sintering (DMLS). The entire shower pan 102 is additively fabricated in some embodiments. The shower pan 102 has at least one additively formed element, such as, by way of example and not limitation, slope geometry, dimensions, aperture, and surface texture.
[0053] It will be understood that the terms such as approximately, about, and substantially as used within the specification and the claims herein allows for a certain amount of variation from any exact dimensions, measurements, and arrangements, and that those terms should be understood within the context of the description and operation of the invention as disclosed herein.
[0054] It will further be understood that terms such as top, bottom, above, and below as used within the specification and the claims herein are terms of convenience that denote the spatial relationships of parts relative to each other rather than to any specific spatial or gravitational orientation. Thus, the terms are intended to encompass an assembly of component parts regardless of whether the assembly is oriented in the particular orientation shown in the drawings and described in the specification, upside down from that orientation, or any other rotational variation.
[0055] It will be appreciated that the terms invention, inventions, embodiment, embodiments, as used herein should not be construed to mean that only a single invention having a single essential element or group of elements as presented. Similarly, it will also be appreciated that these terms encompasses a number of separate innovations which can each be considered separate inventions. Although the present invention has thus been described in detail with regard to the preferred aspects, embodiments, and drawings thereof, it should be apparent to those skilled in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. Accordingly, it is to be understood that the detailed description and the accompanying drawings as set forth hereinabove are not intended to limit the breadth of the present invention, which should be inferred only from the following claims and their appropriately construed legal equivalents.
