U.S. patent application number 11/004247 was filed with the patent office on 2005-06-09 for sill assembly for shower installations.
Invention is credited to Bladen, Roy Victor, Englefield, Derek John.
Application Number | 20050120475 11/004247 |
Document ID | / |
Family ID | 34632216 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050120475 |
Kind Code |
A1 |
Englefield, Derek John ; et
al. |
June 9, 2005 |
Sill assembly for shower installations
Abstract
A pre-formed threshold sill assembly (106) for use in tiled
shower installations (102) allows water to be routed to water
delivery devices such as body spray jets(108) positioned in
columns(112) mounted on a preformed sill(130). Specific connection
pieces, in conjunction with a locking cam (178) and engaging ring
arrangement (180) allow pre-plumbed columns (112) to be quickly
connected to the pre-formed threshold sill assembly (106). Tiling
of the pre-formed threshold sill assembly (106) can be accomplished
according to existing practice.
Inventors: |
Englefield, Derek John;
(Takapuna, NZ) ; Bladen, Roy Victor; (Coatesville,
NZ) |
Correspondence
Address: |
CHRISTENSEN, O'CONNOR, JOHNSON, KINDNESS, PLLC
1420 FIFTH AVENUE
SUITE 2800
SEATTLE
WA
98101-2347
US
|
Family ID: |
34632216 |
Appl. No.: |
11/004247 |
Filed: |
December 3, 2004 |
Current U.S.
Class: |
4/613 |
Current CPC
Class: |
A47K 3/30 20130101; E03C
1/0408 20130101; A47K 3/28 20130101 |
Class at
Publication: |
004/613 |
International
Class: |
A47K 003/28 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 5, 2003 |
NZ |
529,982 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A preformed shower sill frame comprising: (a) a first sidewall;
(b) a second sidewall; and (c) a top wall spanning between the
first and second sidewalls and defining a plumbing channel.
2. The preformed show sill frame of claim 1, wherein the preformed
shower sill frame is formed from a continuous, single piece of
material.
3. The preformed shower sill frame of claim 1, further comprising
an aperture passing through the top wall for permitting a fluid to
pass through the top wall.
4. The preformed shower sill frame of claim 1, further including
indicia disposed on the preformed shower sill frame for indicating
a predetermined location for cutting the preformed shower sill
frame to a preselected length.
5. A shower threshold assembly comprising: (a) a frame attachable
to a support surface; (b) a plumbing channel extending
longitudinally through the frame; and (c) a coupling assembly
coupled to the frame for releasably attaching a device to the
frame.
6. The shower threshold assembly of claim 5, wherein the coupling
assembly is capable of being lowered in the plumbing channel of the
frame during transport.
7. The shower threshold assembly of claim 5, wherein the coupling
assembly includes an indexing member for impeding rotation of a
component coupled to the coupling assembly.
8. The shower threshold assembly of claim 5, wherein the coupling
assembly includes a first threaded portion of a first diameter and
a second threaded portion of a second smaller diameter, and wherein
a fastener is adapted to pass over the second threaded portion to
be engaged by the first threaded portion.
9. The shower threshold assembly of claim 5, further including a
spacer received by the coupling assembly, the spacer having a
thickness which is tapered to aid in providing a level surface.
10. The shower threshold assembly of claim 9, wherein the spacer
interacts with an indexing member of the coupling assembly such
that a direction of the taper of the spacer is oriented in a
selected angular orientation relative to the frame.
11. The shower threshold assembly of claim 5, wherein the device
includes at least one water jet for directing water in a selected
direction.
12. The shower threshold assembly of claim 11, wherein the device
is coupled to a column.
13. The shower threshold assembly of claim 5, wherein the coupling
assembly includes a fluid flow passageway for placing the device
into fluid communication with a fluid supply source.
14. The shower threshold assembly of claim 5, further including a
quick connect assembly having a first interlocking member coupled
to the frame and a second interlocking member for coupling to the
device, wherein the first and second interlocking members are
adapted to interlock with one another to couple the device to the
frame.
15. The shower threshold assembly of claim 14, wherein the first
interlocking member interacts with an indexing member of the
coupling assembly so that the first interlocking member is oriented
in a predetermined orientation relative to the frame when coupled
to the coupling assembly.
16. The shower threshold assembly of claim 5, further including a
cap removably placed over a portion of the coupling assembly,
wherein the cap includes indicia marking a selected height above
the frame to aid a user in applying a covering to the frame.
17. The shower threshold assembly of claim 5, further including a
cap removably placed over a portion of the coupling assembly,
wherein the cap has an aperture allowing a plug to pass through and
connect to the coupling assembly.
18. The shower threshold assembly of claim 17, wherein the cap
includes indicia indicating a selected height above the frame.
19. The shower threshold assembly of claim 5, further including
indicia disposed on the frame for indicating a predetermined
location for cutting the frame to a preselected length.
20. The shower threshold assembly of claim 5, wherein the frame has
a substantially U-shaped cross-section.
21. The shower threshold assembly of claim 5, wherein the device
includes at least one water jet for directing water upon a user,
wherein the water jet is adapted to direct the water inward into a
shower enclosure and away from a door of the shower enclosure.
22. A kit for forming a tileable shower sill, the kit comprising:
(a) a frame having a plumbing channel extending along a
longitudinal length of the frame and having a top surface; (b) a
coupling assembly at least partially extendable through the top
surface; and (c) plumbing adapted to be connected to the coupling
assembly so as to be positioned within the plumbing channel between
the coupling assembly and an end of the frame.
23. The kit of claim 22, further including a first interlocking
member coupleable to the coupling assembly for permitting a support
member to be coupled to the frame in a quick connect manner.
24. The kit of claim 23, wherein the first interlocking member is
indexed such that the first interlocking member is oriented in a
preselected angular orientation relative to the frame when coupled
to the coupling assembly.
25. The kit of claim 22, wherein the coupling assembly and plumbing
are adapted to be disposed within the plumbing channel during
transport.
26. The kit of claim 22, further including a cap removably
placeable over a portion of the coupling assembly, wherein the cap
has an aperture allowing a plug to pass through and connect to the
coupling assembly.
27. The kit of claim 22, further including a cap removably
placeable over a portion of the coupling assembly, wherein the cap
includes indicia marking a selected height above the frame to aid a
user in applying a covering to the frame.
28. The kit of claim 22, further including a support member
attachable to the frame, a first interlocking member coupled to the
frame, and a second interlocking member coupled to the support
member, wherein the first interlocking member is couplable to the
second interlocking member to couple the support member to the
frame.
29. The kit of claim 28, wherein the first and second interlocking
members may be fully coupled to one another through rotation of the
first and second interlocking members relative to one another of
less than 360 degrees.
30. The kit of claim 22, further including a support member
attachable to the frame, a door attachable to the support member, a
hinge set for attaching the door to the support member, a spray jet
attachable to the support member, and plumbing for connecting the
spray jet to the coupling assembly.
31. The kit of claim 30, wherein the support member is internally
preplumbed between the spray jet and one end of the support
member.
32. The kit of claim 31, wherein the internal plumbing of the
hollow support member terminates near a base of the hollow support
member and is terminated to allow connection to the coupling
assembly in a quick connect manner.
33. The kit of claim 22, wherein the frame is preplumbed with the
plumbing.
34. The kit of claim 22, wherein the frame includes indicia for
indicating a predetermined location for cutting the frame to a
preselected length.
35. A method of forming a shower sill using a preformed sill form
having a plumbing channel, the preformed sill form capable of
supplying water to components attached to the preformed sill form,
the method comprising: (a) passing a protruding portion of a
coupling assembly through an aperture of the preformed sill form so
that the protruding portion extends outward of the preformed sill
form; (b) securing the coupling assembly to the preformed sill
form; (c) coupling plumbing passing through the plumbing channel of
the preformed sill form in fluid communication with the coupling
assembly and a fluid source; (d) attaching the preformed sill form
to a supporting surface; and (e) attaching tiling upon the
preformed sill form.
36. The method of claim 35, further including placing a removable
cap over the protruding portion of the coupling assembly, the
removable cap including indicia chosen to identify a selected
height above the preformed sill form to aid a user in applying a
covering to the preformed sill form.
37. The method of claim 36, further including: (a) extending a
shower sill membrane over the preformed sill form; (b) tiling over
the shower sill membrane, and (c) removing the removable cap.
38. The method of claim 35, further including trimming the
preformed sill form to a selected length prior to attaching the
preformed sill form to the supporting surface.
39. The method of claim 38, further including locating indicia
disposed on the preformed sill form and trimming the preformed sill
form at the indicia to the selected length.
40. The method of claim 35, further including coupling a water jet
in fluid communication with the coupling assembly.
41. The method of claim 35, further including placing at least one
tapered shim having a tapered thickness over the protruding portion
of the coupling assembly to aid in creating a level surface.
42. The method of claim 41, wherein the protruding portion is
indexed such that the tapered shim is oriented in a selected
angular orientation relative to the preformed sill form when the
tapered shim is placed over the protruding portion.
43. The method of claim 35, further including coupling an
interlocking member to the protruding portion of the coupling
assembly.
44. The method of claim 43, further including connecting a support
member for supporting a spray nozzle to the preformed sill form by
coupling the support member to the interlocking member in a quick
connector manner.
45. The method of claim 44, wherein the interlocking member is
keyed to the coupling assembly such that when the support member is
coupled to the interlocking member, the support member is located
in a selected angular orientation relative to the preformed sill
form.
46. The method of claim 44, wherein the support member is
pre-plumbed prior to being secured to the preformed sill form.
47. The method of claim 44, further including coupling a panel to
the support member.
48. The method of claim 47, wherein the spray nozzle is adapted to
direct a fluid inward into a shower enclosure and away from the
door.
49. The method of claim 35, further including coupling a water jet
in fluid communication with the coupling assembly and coupling a
support member to the coupling assembly for supporting the water
jet.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to the field of shower
plumbing and construction, and more specifically to the plumbing
and construction of shower sills.
BACKGROUND OF THE INVENTION
[0002] There are two major practices for the installation of shower
assemblies. The first practice involves installing a pre-formed
shower receptor. The pre-formed shower receptor includes a door and
wall panels. The pre-formed shower receptor may be positioned
against a wall, in a corner, or an alcove, or be free standing.
[0003] Instead of installing a pre-formed shower receptor, the
second practice calls for tiling the walls and the floor creating a
shower enclosure. Creating a shower enclosure in this method is
much more labor intensive and time consuming to install, but are
still preferred by many users. Standard construction techniques for
tiled shower installations comprise the formation of a
substantially solid base of lumber or ply materials. Taking the
example of a three-walled alcove, a supporting base may be formed
of ply and timber lining the walls up to a particular height. The
front threshold or sill assembly is typically formed from several
pieces of 2".times.4" solid lumber. In such an installation,
columns for mounting the door and possibly panels are often mounted
on the sill.
[0004] Typical traditional tiled shower installation methods
include, once the base or threshold area have been suitably formed
and the drain exit and other plumbing pre-plumbed, placing a
waterproofing membrane layer (which may be a sheet blanket or
liquid material) over the substructure up to a predetermined height
(often governed by regulations). Over this is next provided a
mortar/bedding mix often reinforced with a metal lath. At this
stage, any tapering of the floor area towards the waste, and
tapering of the sill's top (to drain water back into the shower
receptor area) is performed. Finally, tiles are adhesively set in
place over these layers. Grouting is then performed. At this stage,
final installation of components such as supporting columns and
doors are performed.
[0005] Of recent, the preferences of what consumers want in a
bathroom have shifted. For instance, the typical shower
installation of the past included a single shower rose (shower
head) controlled by faucets or a mixing valve. Showers over bath
installations were also common. At the high end of the market,
additional features were included such as multiple body spray jets
(typically horizontally orientated spray nozzles arranged at
varying heights). While previously restricted to the high end of
the market, the average consumer now wishes to have body spray jets
in a shower and at a more economical price.
[0006] In shower assemblies using a pre-formed shower enclosure, a
void is often present between a wall of the building and a wall of
the preformed enclosure. This void allows the easy routing and
plumbing of a series of body water jets. However, in tiled shower
assemblies, this void is not present and the placement of body
water jets and plumbing involves extensive work as the plumbing
must be routed through the wall. This is a time consuming and
expensive process. Further, since the plumbing is often put in
place before the consumer has selected the shower arrangement
desired, the plumbing often has to be redone to properly locate the
plumbing for body water jets.
[0007] Thus, there exists a need for a shower assembly for tiled
installations that permits the easy routing and installation of
body water jets, that is reliable, easy to install, and meets the
expectations of the end user.
SUMMARY OF THE INVENTION
[0008] One embodiment of a preformed shower sill frame formed in
accordance with the present invention is disclosed. The preformed
shower sill frame includes a first sidewall, a second sidewall, and
a top wall spanning between the first and second sidewalls, the
first sidewall, the second sidewall, and the top wall defining a
plumbing a channel.
[0009] One embodiment of a shower threshold assembly formed in
accordance with the present invention is disclosed. The shower
threshold assembly includes a frame attachable to a support
surface. The shower threshold assembly includes a plumbing channel
extending longitudinally through the frame. The shower threshold
assembly includes a coupling assembly coupled to the frame for
releasably attaching a device to the frame.
[0010] One embodiment of a kit for forming a tileable shower sill
formed in accordance with the present invention is disclosed. The
kit includes a frame having a plumbing channel extending along a
longitudinal length of the frame and having a top surface. The kit
further includes a coupling assembly extendable through the top
surface. The kit further includes plumbing adapted to be connected
to the coupling assembly so as to be positioned within the plumbing
channel between the coupling assembly and an end of the frame.
[0011] One method of forming a shower sill in accordance with the
present invention using a preformed sill form having a plumbing
channel, the preformed sill form capable of supplying water to
components attached to the preformed sill form, is disclosed. The
method includes passing a protruding portion of a coupling assembly
through an aperture of the preformed sill form so that the
protruding portion extends outward of the preformed sill form. The
method also includes securing the coupling assembly to the
preformed sill form and coupling plumbing passing through the
plumbing channel of the preformed sill form in fluid communication
with the coupling assembly and a fluid source. The method further
includes attaching the preformed sill form to a supporting surface
and attaching tiling upon the preformed sill form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing aspects and many of the attendant advantages
of this invention will become better understood by reference to the
following detailed description, when taken in conjunction with the
accompanying drawings, wherein:
[0013] FIG. 1 is a perspective view of one embodiment of a shower
assembly formed in accordance with the present invention showing a
plumbing system supplying water through piping disposed within a
sill assembly and a pair of door support columns to supply a series
of water jets coupled to the door support columns;
[0014] FIG. 2 is a partially exploded perspective cut away view of
the sill assembly and door support column of the shower assembly of
FIG. 1;
[0015] FIG. 3 is a cross-sectional view of one of the support
columns coupled to the sill assembly of the shower assembly of FIG.
1;
[0016] FIG. 4 is an exploded perspective view of the support column
and sill assembly depicted in FIG. 3;
[0017] FIG. 5 is a perspective exploded view of a connection piece,
a cam portion, and a cam sleeve of the shower assembly of FIG. 1;
and
[0018] FIG. 6 is a perspective exploded view of the connection
piece of FIG. 5, and a protective cap and a plug used during the
installation of the shower assembly of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] One embodiment of a shower assembly 100 formed in accordance
with the present invention is depicted in FIGS. 1-6. Referring to
FIG. 1, the shower assembly 100 includes a shower enclosure 102, a
plumbing system 104, and a sill assembly 106. Generally described,
the shower assembly 100 permits the rapid installation of a series
of body water jets 108 in a shower by permitting a section of water
supply piping 110 of the plumbing system 104 to pass through a
cavity or plumbing channel 138 (see FIG. 2) of the sill assembly
106 and through a pair of hollow support columns 112 of the
enclosure 102.
[0020] In light of the above general description of the shower
assembly 100, the individual components of the shower assembly 100
will now be described in greater detail. Focusing first on the
shower enclosure 102, the shower enclosure 102 includes three tiled
walls 114 and a clear glass wall 116. The clear glass wall 116
includes a pair of support members, such as a pair of hollow
support columns 112 coupled to the sill assembly 106. A shower door
120 is pivotally coupled to one of the support columns 112 by a
pair of hinges 118. The support columns 112 are hollow, having an
inner passage permitting the water supply piping 110 to be plumbed
therein. The water supply piping 110 is coupled in fluid
communication with a series of body water jets 108 coupled to the
support columns 112. The body water jets 108 emit substantially
horizontal oriented streams of water upon an occupant of the shower
enclosure 102.
[0021] The shower assembly 100 further includes a plumbing system
104. The plumbing system 104 includes hot and cold supply lines
122H and 122C coupled in fluid communication with a mixer 124. A
pair of control valves 126 selectively control the flow of mixed
hot and cold water through the water supply piping 110 to a shower
head 128 and/or the body water jets 108.
[0022] Referring to FIG. 2 and focusing upon the sill assembly 106,
the sill assembly 106 includes a pre-formed sill form or frame 130.
In the illustrated embodiment, the sill form 130 has a U-shaped
cross section with a pair of legs 132A and 132B of the sill form
130 spaced apart from one another to receive a standard piece of
timber 134 fixed to (thereby becoming part of) a supporting
surface, such as the floor. In the illustrated embodiment, the
standard piece of timber is a 2.times.4, and the legs are spaced
apart between about 3 and about 4 inches, with a preferred distance
of about 3.5 inches.
[0023] The sill form 130 may be screwed to the timber 134 by a
plurality of fasteners 136. The legs 132A and 132B are of
sufficient length such that a cavity 138 is formed above the timber
134, the cavity 138 defined by the inner surface of the sill form
130 and the floor, i.e., timber 134. In the illustrated embodiment,
the legs are greater than about 1.5 inches in length, with a
preferred distance of about 3.75 inches. The sill form 130 may be
formed from any number of rigid and semi-rigid materials, a few
suitable examples being metal and/or metal alloys, such as an
extruded aluminum or an aluminum alloy, and plastic materials, such
as a fiber reinforced cementitious material, a fiber reinforced
plastic, a moldable plastic material, a plastic foam cell material,
or an extrudable plastic material. The outer surface of the sill
form 130 may be textured 139 to increase adhesion of a material,
such as a liquid coating membrane layer 154 for waterproofing the
sill form 130.
[0024] The sill form 130 includes one or more apertures 140. The
apertures 140 are located at the point wherein the support columns
112 of the shower enclosure are attached to the sill assembly 106.
The apertures 140 permit water flowing in the supply piping 110
disposed in the cavity 138 of the sill form 130 to pass through a
top surface 142 of the sill form 130 and into the support columns
112. The apertures 140 may be preformed in the sill form 130 or
they may be cut into the sill form 130, such as on site during the
installation process.
[0025] The sill form 130 may include indicia 143 for marking
preferred locations for cutting the sill form 130 to length.
Moreover, different installations require sill forms 130 of
different lengths. In some instances, a custom length is required
and the sill form 130 may require cutting at a non-standard
location. In other cases, the installation may require a sill from
130 of a more standardized length. The indicia 143 may be placed at
various standard sill form lengths to aid an installer in cutting
the sill form 130 to a selected standard length without having to
measure the sill form 130. Alternately, the indicia 143 may be
placed at predetermined intervals, such as every half inch, with
measurements printed by each indicia 143 indicating the overall
length of the sill form 130 at each indicia to aid the installer in
cutting the sill form 130 to a selected length during custom
installations.
[0026] The indicia 143 may be physical markings, a few examples
being raised ribs or lines extending upward from the top surface
142 of the sill form 130. For instance, a pair of ribs or lines may
be spaced approximately a width of a cutting blade apart for
accepting a cutting blade therebetween for both guiding the
positioning of the cutting blade at the proper location and guiding
the cutting blade during the actual cutting of the sill form 130.
The indicia 143 may also be physical marking which include channels
or notches sunken in the top surface 142 or extending into the top
surface of the sill form 130 to guide the cutting of the sill form
130. The indicia 143 also may be visual markings, such as painted
or printed lines for aiding the selection of a location to cut the
sill form 130 to length.
[0027] Coupled to each of the apertures 140 is a coupling assembly
144. The coupling assemblies 144 are coupled in fluid communication
with the water supply piping 110 disposed in the cavity 138 of the
sill form 130 and with the body water jets 108. Each of the
coupling assemblies 144 include a union 146 and a connection piece
148.
[0028] Referring to FIGS. 2, 3, and 5, the union 146 of the
illustrated embodiment is an elbow or T connection which is
connected in fluid communication with the water supply piping 110
to permit water passage from the water supply piping 110 through
the coupling assemblies 144 and into the support columns 112. A
flange 150 is disposed on the union 146 to impede the coupling
assembly 144 from passing through the apertures 140 and to aid in
the mounting of the coupling assembly 144 to the sill form 130.
[0029] The connection piece 148 extends up from the union 146 and
passes through the aperture 140. A securing nut 152 is associated
with each connection piece 148. During transit, the nut 152 is
removed or threaded on the connection piece 148 within the cavity
of the sill form 130 so that at least a portion if not all of the
connection piece 148 and substantially all of the associated water
supply plumbing 110 rest within the cavity 138 of the pre-formed
sill 130. During installation, the securing nuts 152 are removed,
the connection pieces 148 pushed through the apertures 140, and the
securing nuts 152 reapplied and tightened so that the top surface
142 of the pre-formed sill 130 is sandwiched between the securing
nuts 152 and the flanges 150 disposed on the unions 146. This is
preferably performed after a waterproof membrane 154 has been
applied to the sill form 130.
[0030] Referring to FIGS. 2, 3, and 6, initially the coupling
assemblies 144 may be attached to the sill form 130 by screws 216
threading into apertures 156 in the flange 150. This is typically a
temporary arrangement until the securing nuts 152 are fitted. The
base 158 of the connection pieces 148 may have a larger thread
diameter than the distal end of the connection pieces 148. As best
shown in FIG. 6, this allows a protective cap 160 and water supply
test plug 162 to be fitted at the factory and the securing nut 152
slid over the protective cap 160 to the base 158 for securing
without the protective cap 160 having to be removed.
[0031] FIG. 6 illustrates in greater detail the connection piece
148 in conjunction with the protective cap 160 and plug 162. The
plug 162 is sized and configured to be sealingly received by the
connection piece 148 for the purpose of water pressure testing.
Moreover, the plug 162 prevents water flow out of the connection
piece 148 so that the system can be pressure tested and/or
pressurized prior to installation of the remaining components of
the shower assembly.
[0032] The protective cap 160 includes indicia 212, such as visual
or physical markings disposed on the side of the protective cap
160. The indicia 212 act as a guide to aid in the placement of
material upon the sill form 130 at a predetermined height.
Preferably the indicia 212 marks a maximum finished tile height,
but the indicia 212 may also mark other heights, such as a minimum
tile height. In the illustrated embodiment, the maximum finished
tile height is indicated by a line disposed partially around a
circumference of the protective cap 160.
[0033] The protective cap 160 protects the threads of the
connection piece 148 during installation and allows, with the use
of the plug 162, a plumber to pressure test the system. To remove
the protective cap 160 from the connection piece 148, the plug's
162 hexagonal head is loosened with a crescent wrench or spanner.
The threads of the plug 162 may engage the protective cap 160 to
assist in lifting the protective cap 160 from the mortar/grout
applied to the sill form 130. Alternately the protective cap 160
may be cut with a box knife or similar device leaving a portion of
the protective cap 160 disposed below the finished tile height
and/or imbedded below the tile surface.
[0034] To help rotationally orientate components, such as the cam
portion 178 (which will be described in more detail below), on the
connection piece 148, the connection piece is keyed or indexed. In
the illustrated embodiment, this is provided by one or more keyways
218 (one shown), which are in the form of flat faces which extend
vertically down the opposite sides of the connection piece 148.
These flats or keyways 218 extend at least to, and preferably
below, the bottom edge of the protective cap 160 (see FIG. 6) once
fitted--i.e. they will extend at least to and preferably below the
typical finished tiled surface which may be applied to the sill
form 130. The keyways 218 may be substantially diametrically
opposite each other as illustrated or alternately, may be
misaligned to impede certain components being accidentally placed
180.degree. out of rotation from the correct orientation of the
component.
[0035] Referring to FIGS. 4 and 5, a quick connect assembly 174
will now be described. The quick connect assembly 174 provides
means by which the hollow support column 112 can be fastened to the
sill assembly 106 in a quick connect manner. More specifically, the
quick connect assembly 174 includes an upper interlocking member or
interlocking sleeve 180 and a lower interlocking member or cam
portion 178. The interlocking sleeve 180 is coupled to the bottom
of the hollow support column 112. The interlocking sleeve 180
interacts with the cam portion 178 by a bayonet type action. The
exact rotational orientation of the hollow support column 112 is
defined by the rotational orientation of the cam portion 178. Thus,
the cam portion 178 of the illustrated embodiment is keyed to
interact with the keyway 218 of the connection piece 148.
[0036] Moreover, the cam portion 178 includes one or more keys or
inward protruding flat surfaces 204 and 206 disposed in the inside
of the cam portion 178. These keys or flat surfaces 204 and 206 are
sized and configured to interact with keyways 218 disposed on the
connection piece 148 such that the cam portion 178, when interfaced
with the connection piece 148, is oriented in a selected angular
orientation relative to the sill form. The keys or flat surfaces
204 and 206 of the illustrated embodiment appear as filled in
chords within an inner circular aperture of the cam portion
178.
[0037] The cam portion 178 includes outwardly extending protrusions
208. The interlocking sleeve 180 similarly has inwardly extending
portions 210. During installation, the hollow supporting column is
rotated such that the protrusions 208 on the cam portion 178 may
pass through the gaps between the inwardly extending protrusions
210 of the interlocking sleeve 180. Once the interlocking sleeve
180 has been placed about the cam portion 178, the support column
112 and the interlocking sleeve 180 are rotated (preferably less
than 360 degrees) so that the protrusions 208 on the cam portion
178 overlie the related protrusions 210 on the interlocking sleeve
180, locking the support column to the sill assembly. Detents or
barbs may be provided on the cam portion 178 and/or the
interlocking sleeve 180 to ensure that once rotated into a locked
position, the support column cannot be as easily rotated for
release.
[0038] Turning to FIG. 2 and focusing upon the method of
installation, leaving aside modifications to the rest of the shower
wall interiors, a membrane layer 154 is generally applied prior to
the installation of the securing nuts 152 which go over the top of
the membrane layer 154. The preference is for a liquid coating
membrane layer 154, although solid sheet type membrane layers 154
may also be used. Solid sheet type membrane layers 154 will need to
be trimmed to allow the connection pieces 148 to protrude there
through. Preferably, the protective caps 160 are positioned over
the top end of the connection pieces 148 and the water supply test
plugs 162 fastened to the connection pieces 148, if not already
present, before application of the membrane layers 154 or other
layers.
[0039] Referring to FIGS. 2 and 6, next a bedding layer 164 of mud,
mortar or other suitable mix is applied. This bedding layer 164 is
usually reinforced with a mesh 166. The installer can then build
upon the bedding layer 164 up to a desired thickness and contour
appropriate for the chosen tiles as per normal practice. The
protective cap 160 includes indicia 212, such as a visual line or
physical mark that indicates a maximum mortar/tile height. The
indicia 212 should be used as a guide for installers such that they
do not build up past the maximum height of the finished tiled
surface.
[0040] Next, tiles 168 may be applied using a suitable tile
adhesive 170. After this stage, the water supply test plug 162 and
protective thread cap 160 may be removed and a sealant layer (not
shown) optionally laid over the tiles 168. This sealant layer may
be formed from a compressible or flexible sealant type material to
prevent the ingress of water into the installation.
[0041] Referring to FIG. 4, a tapered spacer or washer 172 may be
used to help level the surface should an incline have been provided
to assist in draining of water from the tiled surface back into the
shower pan or base. The tapered washers 172 have a thickness that
is tapered across the width of the washer. Preferably, a set of
tapered washers 172 are provided, the set including tapered washers
172 of various tapered thickness. One or a combination of these
tapered washers 172 may be used as required. These tapered washers
172 may be keyed to interact with a flat or keyway 218 (FIG. 6)
disposed on the connection piece 148 such that the direction of
taper of the tapered washers 172 is oriented perpendicular to the
length of the sill form 130.
[0042] A flat washer 176 may be provided over these tapered washers
172, followed by a cam portion 178 and a securing nut 214. The
securing nut 214 may be tightened down to hold everything firmly
upon the connection piece 148.
[0043] Preferably, the hollow support column 112 is pre-plumbed
with an internal conduit 182 supplying water to the body water jets
108 which are positioned at appropriate intervals along the height
of hollow support column 112.
[0044] Connection of the internal conduit 182 may be via a number
of methods. For instance FIG. 4 illustrates a coupler 186 which may
be threaded to the connection piece 148. Alternately, the internal
conduit 182 of the hollow support column 112 may be coupled to the
connection piece 148 by a quick to connect type fitting, such as a
John Guest type fitting. A quick to connect fitting allows the
coupler 186 of an extendable portion 190 of the internal conduit
182 to be pulled down and fitted to the connection piece 148 by
pushing the coupler 186 toward the connection piece 148.
[0045] In an alternative arrangement the internal conduit 182 is
rigid and non-extendable and the coupler 186 is a push fit coupler.
The push fit coupler 182 may be pushed inside the top end of the
connection piece 148 to provide a water tight seal therein as the
hollow support column 112 is coupled to the sill assembly 106. As
should be apparent to the those skilled in the art, although two
types of couplers are illustrated and/or described for coupling the
internal conduit 182 to the connection piece 148, other couplers
are suitable for use with the present invention and are within the
spirit and scope of the present invention.
[0046] The hollow support columns 112 are connected to the sill
assembly 106 in a quick connect manner as described above. This
secures the hollow support column 112 to the threshold sill
assembly 106 such as illustrated in FIG. 3. The shower enclosure
102 may be completed as substantially shown in FIG. 1 by the
installation of a pair of side panels 196 and 198 and by coupling
the door 120 to one of the support columns 112 by a pair of hinges
118.
[0047] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention. For instance, according to one embodiment
formed in accordance with the present invention there is provided a
pre-plumbed shower threshold sill assembly including a sill form,
one or more apertures in a top surface of the sill form through
which a connection portion for a water conduit can protrude, and
plumbing within the sill form leading from the connection portion
to an end of the sill form.
[0048] At least part of the connection portion that extends above
the top surface of the sill form may be threaded. The sill assembly
may include a nut complementary to the threaded portion of the
connection portion, the arrangement between the nut and connection
portion being such that the nut may be loosened and positioned near
the threaded free end of the connection portion to allow the
connection portion and connected plumbing to be lowered
substantially within the threshold/sill form during transport. The
nut can be subsequently tightened to raise the lowered connection
portion to its correct height for use, and to lock the connection
portion and associated plumbing into place for use.
[0049] The connection portion may be coupled to a union that
substantially comprises an elbow or T-shaped coupling member. The
threaded portion of the connection portion may be keyed or indexed
to limit the rotational orientation of one or more additional
components placed over same. The threaded portion may be keyed or
indexed by the presence of at least one longitudinal slot or flat
face on its outer surface. The flat face may be oriented so as to
be parallel to an imaginary line tangent with the outside surface
of the threaded section. The sill assembly may include one or more
apertures in the top surface of the sill form, wherein the
connection portions extend through the apertures, and wherein the
connection portions are connected together in parallel by the
plumbing.
[0050] The plumbing may include one or more of a flow control
valve, a mixer, a pressure regulating means, a body spray jet, and
a shower head. The end of the plumbing at an end of the sill form
may be terminated by a connection means for the attachment of a
supply pipe or plumbing. The outside of the sill form may be
textured to improve the adherence of a liquid membrane coating. The
sill form may be ribbed, or otherwise modified on its inside to
increase its rigidity. The sill form may be of a material able to
be trimmed to length by a handsaw, power saw, or grinder. The sill
form may be made of at least one of the following materials:
aluminum, an aluminum alloy, another metal or alloy, a moldable or
extrudable plastic material, a fiber reinforced plastic, and a
fiber reinforced cementitious material. The sill form may be
precoated with a waterproofing membrane material.
[0051] The connection portion may be threaded and keyed, wherein
the keying does not interfere with the threading of components upon
the threads of the connection portion. The connection portion may
be coupled to a union comprising substantially a right-angled elbow
or a T-shaped joint. The connector portion may terminate in a
flange disposed near or at the termination of the threads of the
connection portion. A nut or associated nut flange may be threaded
upon the threads of the connection portion to sandwich the
thickness of the top surface of a preformed sill of the threshold
assembly between the flange and the nut. The flange may accommodate
screws or mechanical fastening means allowing the flange and
connection portion to be fastened to the preformed sill form. The
threaded sections of the connection portion may include at least
two different outside diameters adjacent each other on the portion
of the connection portion which extends above the top surface of
the sill.
[0052] The sill assembly may include a cam portion which is able to
engage with an engaging portion, the cam portion being
substantially annular and disc-like and including at least one
outwardly directed feature adapted to extend into a hollow central
portion of the engaging portion. The cam portion may include a key
which interacts with a keyway or face on the connection portion.
The sill assembly may also include an engaging portion, wherein the
engaging portion is associated with a column or structural element
which is able to be connected to the cam portion. The connection of
the engaging portion to the cam portion may be by substantially a
bayonet action. The cam portion may be able to be secured to the
threaded portion of the keyed connection portion, substantially as
described above, by placing over same, and tightening a retaining
nut or a retainer mechanism over the threaded portion.
[0053] The sill assembly may include at least one of the following:
locking washers, spacer shims (washers), tapered wedge washers
which taper in thickness, and a protective capping piece--all
characterized by being placeable over the threaded keyed portion of
the keyed connection portion.
[0054] In accordance with one embodiment formed in accordance with
the present invention there is provided a kit for forming a
tileable shower sill. The kit may include a sill form with at least
one aperture in a top surface, at least one keyed connector portion
with a threaded keyed end passable through the aperture, and
plumbing connected or connectable to a the keyed connection portion
to an end of the sill form. The kit may also include a protective
cap removably placeable over a keyed threaded end of the keyed
connection portion. The protective cap may be a one piece unit. The
protective cap may have an aperture disposed in the top allowing a
plug to pass through and connect to the end portion of the
connection portion. The kit may include a cam portion,
substantially as described above. The kit may also include at least
one hollow support member having an engaging portion selectively
couplable to the cam portion.
[0055] The kit may also include a shower door attachable to the
hollow support member, a return panel, and a hinge set for
pivotally coupling the shower door to the hollow support member,
spray jets positioned or positionable in the hollow support member,
and plumbing for connecting the connector portion to the spray
jets. The hollow support member may include at least one spray jet
and the hollow support member may be internally preplumbed. The
internal plumbing of the hollow support member may terminate near
the base of the hollow support member, and may be terminated to
allow connection to the keyed connection piece with which the
hollow support member is associated. The keyed connection piece and
terminated end of the internal plumbing of the hollow support
member may be able to form a quick connection, the quick connection
including a push-fit or bayonet fit connection.
[0056] According to a further aspect of one embodiment formed in
accordance with the present invention there is provided a method of
forming a pre-tiled shower sill/threshold capable of supplying
water to components attached or placed partway along the length of
the sill, the method comprising:
[0057] optionally trimming a sill form to length;
[0058] providing aperture(s) in the top of the sill form where
supporting structures are to be attached to the sill;
[0059] passing a threaded keyed portion of a keyed connection
portion through the aperture and securing in place with a nut;
[0060] providing plumbing within the sill form to an end of the
sill form and connecting to a water source in the existing
structure; and
[0061] securing the sill form to the floor or supporting
surface.
[0062] The method may also include:
[0063] placing a removable cap over the exposed threaded end of the
connection portion(s), the length of the cap or markings on the cap
being chosen to signify the height of at least one of: the finished
tile surface and the height of mortar substrate under the
tiles;
[0064] extending the shower floor membrane over the sill forms;
[0065] applying a cementitious substrate over the sill form;
[0066] tiling over the substrate; and
[0067] removing the cap(s).
[0068] The method may also include:
[0069] placing tapered shims or washers over the exposed keyed
portion of the connector portions to create a level surface;
[0070] placing a keyed cam portion, substantially as described
above, over the exposed keyed portion of the connection portions
and securing the keyed cam portion in place with a nut or ratchet
engaging fitting device;
[0071] connecting at least one hollow supporting member having an
engaging portion attached thereto to the shower sill, the engaging
portion interlocking with the cam portion to couple the hollow
support member to the shower sill; and
[0072] finalizing any plumbing connections within the hollow
supporting member, either prior to or at the time of its
attachment.
[0073] The hollow support member may be pre-plumbed. The method may
include attaching either or both door panels and return panels to
the hollow support members. The hollow support member may or may
not include at least one of the following: spray jet, oriented
substantially horizontally, a shower rose, or faucets.
[0074] The method may utilize a pre-formed shower sill. This
pre-formed shower sill is typically a hollow or open element (e.g.
U-shaped or C-shaped) to allow internal plumbing to be suitably
positioned or provided within a cavity formed by the pre-formed
shower sill.
[0075] Preferably, the pre-formed sill acts as a suitable
supporting substrate for finishing layers of mud, mortar or bedding
mix, adhesive, and tiles to be overlaid. In this respect it is
preferable that the sill is relatively rigid and resistant to
flexing so as to avoid cracking of any overlying layers. Suitable
strength and rigidity can be accomplished by a number of means
including suitable choice of materials and appropriate design. It
is anticipated that the typical skilled tradesperson would be well
acquainted with aspects of design and material to construct a
suitable sill in light of this detailed description. For instance,
and by way of example (but not limited to), materials of
construction may include various metals including aluminum and its
alloys, various plastic materials, including moldable or extrudable
materials, and fiber reinforced plastic materials.
[0076] Elements of design which may be used to improve strength and
rigidity can include internal ribs and reinforcing elements of
different materials. A separate insert which fits inside the sill
form after it has been plumbed may also be considered to improve
strength. Injecting expandable foams is another option, which can
increase strength and rigidity as well as providing additional
internal insulation to plumbing provided therein.
[0077] The environment in which the sill is to be used may also be
considered. In preferred methods of use of the present invention
there is an overlying waterproof membrane layer which will protect
the pre-formed sill from water impregnation. Hence while materials
such as steel, which is susceptible to corrosion by water and air,
may be considered and are suitable for use with the present
invention, it is preferred that a suitable anti-corrosive coating
(e.g. zinc coating) or protective coating (e.g. plastic or epoxy
coating) be used.
[0078] The pre-formed sill/threshold may take a number of shapes.
In cross section the pre-formed sill/threshold is preferably hollow
so as to allow for the passage of internal plumbing there through.
Accordingly the pre-formed sill/threshold may be formed to have a
square shaped cross section, though in preferred embodiments the
cross section of the sill is U-shaped or top hat shaped. The cross
section need not be constant along the entire length. It should be
considered however that for most embodiments of the present
invention the sill/threshold will be overlaid with various layers
of materials and finally finished with tiles. Accordingly it is
envisioned that in most cases the major outer surfaces of the
pre-formed sill will be substantially flat and external top and
front/back faces can be either perpendicular to each other or
tapered (with a slight incline applied to the top surface to assist
water drainage).
[0079] In plan view, the shape of the pre-formed sill may vary. In
the simple embodiment the sill may be substantially linear. However
in more sophisticated embodiments, the sill may be curved, or
perhaps curved along only part of its length. Angles may also be
introduced so that the final sill can take any of a number of
possible shapes according to user and manufacturer preferences.
This would allow the pre-formed sill to be used in various designs,
as well as alcove, corner, and angular showers, which extend from
one or more walls etc. The pre-formed threshold/sill may also be
made from material which can be cut to size on site. This would
allow a user to trim the pre-formed threshold/sill to fit a
particular installation, using commonly available tradesperson/home
handyman tools such as handsaws, power saws, hacksaw and/or
grinders. The choice of material will be a consideration in such
embodiments.
[0080] Modifications may be made to the outer surface of the sill.
For instance, in preferred installations there will be a membrane
layer applied directly over the sill. The membrane layer may be a
sheet of material or a liquid membrane coating. Accordingly the
outer surface of the pre-formed sill could be modified to increase
adherence of liquid coatings. This might be accomplished by
texturing so as to allow a keyed bond, or by coating with materials
to which the applied membrane coating is particularly adherent.
[0081] The pre-formed sill should ideally contain provisions for
fixing to the floor and/or supporting substrate. For a pre-formed
sill of "U" or top-hat cross sectional configuration, suitable
aperture holes may be provided or drilled in the lower vertical or
lower outwardly extending flanges. This enables the pre-formed sill
to be mechanically fastened to a floor by devices such as screws,
etc. Adhesive bonding may also be considered.
[0082] The use of separate connectors may also be considered in
various embodiments as well, e.g. a channel section fixed to the
floor over which the sill is positioned. These may click together
for fitting or rely on mechanical or adhesive fastening. Various
fastening tabs may also be formed or attached to various points
along sills of other cross sectional configuration.
[0083] Typically there is provided in the top surface of the sill
one or more apertures through which plumbing may extend. While such
apertures may be formed on site, allowing the installer to
precisely locate apertures according to the shower equipment (e.g.
doors and supporting columns, etc.) to be used in conjunction with
the sill, preference of the present invention is for these
apertures to be pre-formed. By pre-forming the apertures, it is
also possible to pre-plumb (and pressure test) a threshold/sill
assembly which can assist in minimizing warranty problems after
installation and significantly improve installation time. In the
preferred embodiment of the invention to be described later, the
use of the specific plumbing hardware described below can further
aid quick and accurate installation of shower equipment (e.g.
supporting columns for doors, etc.).
[0084] Ideally in the pre-plumbed sill/threshold assembly, there
are provided connection pieces able to extend above the apertures
in the top surface of the pre-formed sill. These are connected
within the interior of the threshold sill assembly to lead to at
least one end of the sill assembly. The plumbing at this end may be
suitably terminated either by cutting to length, or provided with a
suitable typical plumbing connection piece to allow connection to
existing plumbing within the wall of the existing building
structure. In practice, additional plumbing within the wall or from
the floor may be required to route water from a shower's faucets,
mixer, or diverter into the plumbing of the sill. This however may
be performed by standard plumbing practices and typically
accomplished by the plumber at the time of installation of the
present invention.
[0085] The preference for most embodiments of the present invention
comprising a pre-plumbed threshold sill assembly is for the top
portion of the connection pieces extending above the apertures in
the top of the sill to be threaded. Threading can provide a number
of potentially realizable advantages including allowing easy
connection of other components to the connection piece--the
connection piece thereby acting as both a locating and
partial-supporting element for connected fixtures.
[0086] Additionally however, the threads provide a useful advantage
during transport in that a securing nut can be wound back until it
is positioned near the top of the thread. At this point, the
securing nut will rest on the top of the threshold sill assembly
while the rest of the plumbing is lowered so as to be disposed
within the hollow interior of the pre-formed sill. When preparing
for installation, the securing nut can be tightened so that the
connection piece, with which it is associated, is raised to its
correct height and is locked into position with respect to the top
of the sill. Ideally a flange formed integrally with the connection
piece presses against the underside of the top surface of the sill
while the securing nut presses against the top surface of the
sill.
[0087] Alternatively the securing nut can be fitted to the
pre-plumbed assembly when it is separate of the preformed sill. The
pre-plumbed assembly can be transported within the sill assembly,
or even separately thereto. During assembly, the securing nut can
be removed, the end of the connection piece passed through the
aperture in the sill assembly, and the securing nut reattached to
the threaded end of the connection piece and tightened.
[0088] While the aforesaid method, with the securing nut acting as
the primary means of securing the pre-plumbed assembly to the sill,
is suitable for techniques where liquid membrane layers are
applied, the arrangement can be a little troublesome when blankets
are used. Attempting to get blanket layers to adequately seal about
and sit over the nut (which rests above the top surface of the
sill) may be problematic. To address this issue, the illustrated
embodiment has a provision for securing the connection portion to
the sill by means in which the top of the sill remains
substantially flat and level up to the protruding connection
portion. A blanket membrane with an aperture conforming to the
position and diameter of the protruding connection portion can then
be placed over the connection portion and flat against the top of
the sill. The securing nut and washers can then be fitted to
sandwich the blanket membrane beneath it.
[0089] The underside of the connection piece may take a number of
forms. In preferred embodiments it comprises substantially an elbow
to allow for the ready connection of a pipe leading to an end of
the sill assembly. Where more than one connection piece is used to
provide water above the top surface of the sill, additional
connection pieces may comprise a T-connection on the underside of
the top surface. However, to allow for balanced pressure and flow,
various other methods and connection pieces may be considered.
[0090] In various embodiments of the present invention, which are
pre-plumbed, water is eventually routed to water delivery devices
positioned above the sill structure. While various devices may be
used, it is envisioned that the most common form of water delivery
device is a body spray nozzle or jet. These will typically be body
spray jets, which provide a substantially horizontal spray of water
or mist against the body of the user of the final shower assembly.
A problem in the past has been the difficulty in providing water to
such jets and manufacturers have been largely restricted to
specifically designed shower units which are often free standing or
wall mounted. However, the plumbed threshold sill assembly formed
in accordance to the present invention provides a relatively easy
method of routing water to such devices positioned above a sill
assembly, even in instances where the threshold sill assembly is to
be tiled according to substantially traditional techniques.
[0091] In the past this option was not available and any body spray
units would need to be installed on existing walls of the building
structure, or shower panels directly attached to walls of the
building structure. Attempting to route water to free standing
columns (i.e. columns or supports not directly attached to an
existing wall of the building structure) was problematic and
typically required visible overhead plumbing. A further
disadvantage of panels positioned against existing walls of the
building structure is that they typically direct the spray towards,
or substantially towards, the door of the shower assembly. Many
shower doors do not provide adequate sealing to prevent such
volumes of spray from leaking outside the door. Hence, as will be
seen later, the present invention in its various forms can provide
a shower assembly in which spray jets can be provided in structures
positioned above the sill assembly, and oriented in a manner in
which they spray away from the door. This represents an advantage
over what was achievable before the present invention.
[0092] In the preferred embodiment of a shower assembly or
installation kit, hollow support members having internal plumbing
supplying water delivery devices such as body spray jets and
nozzles are used. While the exact details may be varied in
different embodiments, for simplicity the description will
generally be restricted to such an arrangement, although it should
be apparent to those skilled in the art that other arrangements are
suitable for use with and are within the spirit and scope of the
present invention.
[0093] Preferably in such an arrangement, use is made of a cam
locking system (which will be described further later), and which
is the subject of the inventor's separate U.S. patent application
Ser. No. 10/804,573, filed Mar. 18, 2004, and entitled Connection
Assembly Apparatus and Method, the disclosure of which is hereby
expressly incorporated by reference. While such an arrangement does
not need to be used, a much easier installation with a tidier
finish can be accomplished by using such an arrangement. Again the
following description will be centered predominantly on such an
arrangement being used, although it should be apparent to those
skilled in the art that other arrangements are suitable for use
with and are within the spirit and scope of the present
invention.
[0094] The connection portion extending above the top surface of
the sill has been previously mentioned and described. However a
desirable further feature of such a connection portion is that it
is keyed in at least part of the portion extending above the top
surface of the sill. This keying allows for the accurate
orientation of additional components which may be placed above the
top surface of the sill during finishing of an installation. It
also allows the taking into account of height variables and height
adjustability to accommodate varying thickness of substrates. These
may, for instance, include spacers, various shims and washers,
tapered shims and washers, locking cams, etc. There are a number of
reasons and potentially realizable advantages for providing such a
keyed system. For instance it is relatively common practice for
tilers to provide a slight incline in the finished top surface of
the sill so as to drain water back towards the inside of the shower
assembly. In such a case the tapered shims or washers may be
required to level off the top surface of the sill assembly,
immediately about the extending connection portion, so as to allow
the accurate vertical orientation of subsequently attached
components. For instance, where the interlocking cam connection
system is used, it is preferred that the cam be in a horizontal
plane if the resulting attached column is to be truly vertical.
Providing a keyed relationship between such tapered washers and the
connection piece about which they are placed, helps hold the
washers and spacers in the correct orientation and prevents their
rotation during subsequent finishing of an installation.
[0095] Keying of the top portion of the connection piece may be
accomplished in a number of manners. Ideally one or more slots,
keyways, or faces may be provided through the threads so that they
do not interfere with the function of the thread themselves. The
interacting washers or cams etc. may then merely include one or
more protrusions which extend within these slots, keyways, or faces
as they are slid down the connection piece. Various numbers of
slots and other keyed arrangements may be considered in various
embodiments of the invention, though the slot, keyway, or face
arrangement is considered a preferred embodiment.
[0096] Also associated with the connection piece may be a
"Protective Cap" which can be slid over the top end of the
connection piece preferably before an installation operation. The
primary reason for providing this cap is to protect the threads and
opening of the connection piece from foreign material, which may
interfere with subsequent operation. Hence a plastic (or other
material) cap may be provided.
[0097] The cap may include an aperture in the top end allowing it
to be used in conjunction with a plug. Such a plug may pass through
the aperture in the top end of the protective cap and be threaded
into internal threading on the top end of the connection portion,
though several alternate options exist. Hence the plug may be
screwed into the internal threaded section of the connection
portion which enables the preplumbed assembly to be blanked off for
pressure testing by the plumber.
[0098] As an alternative, the protective cap, which covers the
threaded section of the connection portion protruding above the
threshold, may be modified by incorporating into its top a male
threaded section which acts as a plug when screwed into position.
The protective cap has smooth interior walls (i.e. the walls
disposed against the threaded portion of the connection portion are
smooth and not threaded) but has a reverse taper on the outside so
as to allow easy removal from mortar or grout. The integral "union
plug" has a hexagonal nut molded (but not exceeding the protective
cap diameter) to the top to aid and assist rotation and removal of
the protective cap from the threaded section of the connection
portion and from the mortar/grout once the sill is tiled.
[0099] A further alternative method is to form a hole in the
protective cap and have a union plug as a separate component which
has male threads and a hexagonal head. The union plug may be
manufactured from a rigid material, one suitable example being a
metal, such as brass. For assembly purposes, the protective cap
would be placed over the threaded connection piece, then the plug
screwed into position via the internal thread. Once screwed into
position, the plug would act as a seal permitting the plumbing of
the system to be pressure tested. Generally the water pipes are
capped with bungs and left under pressure for some time during
construction until after wall linings and tiling has been
completed. After tiling has been completed, the main water pressure
is turned off, the piping drained, and the bungs removed for
plumbing decorative fixtures and faucets thereto. Plugs generally
have to withstand water pressure for a considerable amount of time
during construction.
[0100] Although various embodiments of plug and cap assemblies have
been discussed, for the remainder of the specification, the various
options shall be discussed synonymously unless specifically stated
or expressed.
[0101] The cap may include indicia to act as a guide as to the
maximum height of the finished mortar or substrate prior to
application of the tiles or marble surface which is to be built up
over the sill. It can also indicate maximum finished tile height.
The indicia may come in many forms, a few suitable examples being
the bottom edge of the cap and a predetermined visual or physical
mark or indicator on the side cap, such as a line drawn partially
or fully about a circumference of the cap.
[0102] The indicia may be used to indicate to a user a height which
any finished tile (or other surface) mortar or grout should not
extend above if the remaining components are to be accurately and
reliably connected. Hence there is provided an effective visual or
physical guide for the finishing of the layers overlying the
pre-formed sill.
[0103] A typical shower installation with doors and body spray jets
will now be described by way of example only. Again this is
representative of various other embodiments which may take effect
in various embodiments of the present invention. It should also be
envisioned that the various steps may be modified according to
local practices, which do differ from region to region. It is
envisioned that the present invention is relatively flexible and
can accommodate such variations in local practice, and changes in
governing regulations for wet area installations. Hence the
following description should be regarded as representative guide
only and that the skilled trades person will be able to adapt the
method of the description to accommodate their preferred and local
practices.
[0104] In the present example, it is assumed that an apron bath in
a three-walled alcove is being retrofitted with a tiled shower
installation. Accordingly, initial preparatory steps should be
performed such as removal of the bath and supporting structure.
This should be followed by attending to in wall pre-plumbing such
as the routing of water to a mixing valve assembly volume control
valves or faucets and directing water to the vicinity of outlet
devices such as shower roses, hand held spray devices, and other
water supply devices that are to be provided within a shower
installation. Additionally a water supply should be routed to a
point near one end of the threshold sill assembly that is to be
formed. In the present invention it is envisioned that a
pre-plumbed threshold sill assembly is being used.
[0105] The threshold sill assembly will be attached to the floor at
a suitable time. If necessary the threshold sill assembly may be
trimmed to size to accurately fit within the opening. Most tiled
shower installations will also require a receptor base to be built
up and wall linings to be initially applied. The attachment of the
threshold sill assembly to the floor can be integrated into these
steps.
[0106] At the time of installing the pre-plumbed threshold/sill to
the floor, the securing nut for the connection portion should be
tightened. This will tightly fix the connection portion to the
pre-formed sill, and extend the top exposed portion of the
connection piece to the correct height above the top surface of the
sill. A protective cap should also be positioned over the top end
of the connection piece at this time, though preferably this has
been installed at the factory. The end plumbing connection from the
end of the pre-plumbed threshold sill assembly should also be
attached to the tempered water supply from the mixing valve or
faucets at the time of installation of the threshold/sill assembly.
Pressure testing of the plumbing may also be performed.
[0107] The next step is installation of a shower drain and lumber
supports between joists for membrane support. A waterproof membrane
is provided over the shower base and sill. This should be
appreciated that the receptor, in the context of the present
invention, will generally mean the bottom lower region of the
shower installation. In many tiled installations a separate
receptor portion will not be visible and the vertical walls will
extend vertically down to meet the bottom tiled floor
assembly--such installations being typically different in
appearance to standard molded receptor and panel assemblies. Many
regulations in different regions require the membrane layer to
extend to certain height from the floor of the shower to above and
beyond the threshold installation. Thus the term shower tray is
used herein for typically referring to that portion of the base of
the shower up to the typical finishing height of the waterproofing
membrane coating.
[0108] Hence the liquid membrane coating or sheeting/layer may be
applied according to standard techniques. According to local
practice the liquid coating (e.g. "HOT MOP.TM.") or sheeting
blanket is overlaid over the threshold/sill and tray areas of the
shower as per normal practice and regulations.
[0109] Typically next, various bedding mud and mortar layers are
built up in the shower tray region with a suitably thick layer of
this material built up over the threshold/sill. Again local
practice is relied upon, and reinforcing materials such as metal
lath, or meshes are often incorporated into such layers. At the
time of providing such a layer over the threshold/sill assembly,
consideration is given to the maximum height indicated on the
protective cap to ensure that the finished tile surface will not
extend above the predetermined and indicated maximum levels
indicated on this protective cap. It is however acceptable that the
finished tile surface be below this predetermined indicated
level.
[0110] After the bedding/mortar layer, suitable tile adhesive is
generally applied and the tiles installed. Grouting typically
follows.
[0111] At this stage the protective cap is removed or cut away and
a support washer placed over the exposed threaded connection piece.
The primary purpose of this support washer is to help spread the
load of additional components as they are tightened down against
the top surface of the tile. This support washer may be partially
resilient or compressible, and may comprise a metal or plastics
material.
[0112] Any preformed tapered shims or washers which counter any
slope or incline which has been formed by the tiler into the top
surface of the sill are applied. These can be used singly or in
combination to counter the slope present so as to provide a
finished horizontal or level top surface.
[0113] Once the top of the washers have been leveled to horizontal,
a cam portion is rotated appropriately and positioned over the
threaded portion of the connection piece. Again the keyed
relationship between the cam and top end of the connection portion
will help suitably orientate the cam portion and maintain this
orientation. Ideally the keyed arrangement should be such that the
cam portion can only be placed over the connection piece in the
correct orientation. This is assisted by the use of integrally
marked arrows, and indicators indicating the direction of
orientation and degree of thickness variation, which is typically
greater towards the inside of the shower receptor. This will be
particularly important, as the correct rotational alignment (and
slope adjustment if required) of the supporting columns (see later)
is dependent upon correct rotational orientation and alignment of
the cam portion with the horizontal plane.
[0114] Finally, at this stage, a tightening nut is placed on the
connection piece and tightened down against the cam portion.
Locking washers may also be included.
[0115] At this stage, final assembly of the shower front is
generally accomplished. Ideally a pre-plumbed hollow support member
is used. This support member will typically comprise a hollow
element, which is pre-plumbed, and which already contains body
jets, or other spray and water delivery devices in its outer walls.
Hinges or fixing means for doors and panels may also be provided,
or pre-drilled apertures for the subsequent fixing of such
components.
[0116] Associated with the bottom end of the hollow support member
is a locking sleeve which can interact with the cam portion.
Ideally this cam portion interacts in a bayonet type action
allowing the hollow support member (and interlocking sleeve) to be
positioned over the cam portion and lowered down to substantially
contact the top surface of the tiled sill and/or washers etc., and
then rotated to orientate and lock/secure the support column in
place. At this stage, the support column should be resistant to
upward lifting movements. The arrangement should also be such that
the support column can only be placed and fitted over the cam
portion in one orientation, this being the correct orientation.
Hence, once fitted, the hollow support portion should be in such a
position that it is correctly orientated (i.e. rotational
orientation) such that door hinges, spray jets, and fixing devices
or means for other components, are orientated in the correct
direction.
[0117] Ideally, the internal plumbing of the column is such that a
rotatable or push-fit type of connection is achieved with the
connection piece as the column is lowered into position. However,
the use of a flexible internal pipe portion, which can be extended
down to allow connection to the connection piece is also suitable
for use with the present invention. A variety of different
couplings and fittings which allow a watertight connection to be
made are known and are suitable for use with the present
invention.
[0118] Typically next, the finishing of the shower front is
accomplished. This generally involves the fixing of side return
panels, doors, and etc. as well as fitting any top reinforcing or
strengthening rails, etc.
[0119] This represents a typical installation according to certain
embodiments of the present invention and, as mentioned before,
specific embodiments and methods of installation may vary within
the scope of the present invention.
[0120] By way of further example, some further comments are made on
the nature of the cam portion and associated interlocking sleeve
assembly. This general arrangement may be as described in
previously mentioned U.S. patent application Ser. No.
10/804,573.
[0121] In one respect, such an arrangement as described in U.S.
patent application Ser. No. 10/804,573 may be described as a
connection system consisting of a pair of cooperatingly formed
engaging portions, one of which engaging portions is coupled to a
member to be attached to a surface or structure. The other engaging
portion is attachable to the surface or structure (which may be
during or post-construction depending on the embodiment). The
engaging portions preferably interact and engage with a partial
rotational and/or bayonet type action. Preferably the connection
arrangement is substantially hidden, except by user choice, when
the member is ultimately attached to the surface or structure by
cooperative engagement of the engaging portions. Preferably one
engaging portion can be considered a cam or cam-like arrangement
which interacts with the second engaging portion which can be
likened to an annular sleeve. The engaging portions are preferably
hollow or have removed portions to allow plumbing or services to
pass from the surface (or structure) through to the building
element being attached. The building element may be pre-plumbed
and/or pre-wired.
[0122] Preferably, one of the engaging portions is a cam portion is
typically disc-like in appearance with outwardly extending flange
portions are present at the top outer face of the engaging portion.
Preferably these outwardly extending flange portions interact with
similar flange portions disposed on the other engaging portion.
[0123] The other of the engaging portion is preferably annular in
appearance and is also hollow in its middle to allow plumbing,
and/or electrical services there through. Extending radially
inwards into this cavity/aperture are flange portions which
interact with the flange portions on the above-described engaging
portion. These are positioned and sized commensurately, so that the
flange portions overlap when suitably rotated. The engaging portion
is affixed to or integrated to a member such as a support
column.
[0124] In practice the column assembly can be lowered over a first
engaging portion secured to a surface or structure. Once lowered,
the assembly can be rotated so that flanges of both the engaging
portions engage/interlock with each other. This arrangement then
secures the column assembly from being removed from the surface or
structure. The assembly is then securely fastened to the sill
surface with no externally visible evidence of attachment.
[0125] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention.
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