Shower pan drain assembly system

Abstract

An integrated shower base designed for improving the drainage of a tile shower is disclosed. The shower pan may be custom fabricated and molded with a depression surrounding a drainage opening for receiving a one piece floor drain. The pan and floor drain are welded together to prevent leaking. The floor drain contains weep holes so that water that seeps through the mortar on the shower floor and into the shower pan can drain properly without leaking. The floor drain also contains a reservoir for holding water that drains through the regular shower drain and also for water that seeps through the shower floor. A mortar guard is placed over the weep holes to prevent the holes from becoming clogged. A drainage mat is placed over the shower pan to help water seepage flow to the floor drain.

1 . A method for making a shower pan comprising
 providing a sheet of a sheet metal having a length and a width;   fabricating said sheet of sheet metal into a shower pan, said shower pan having at least a base area and one or more sidewalls extending upwardly from said base;   providing an opening in said sheet metal for receiving a drain;   welding said drain to said sheet metal to form a unitary shower pan.   
   
   
       2 . The method according to  claim 1  wherein said sheet metal is stainless steel. 
   
   
       3 . The method according to  claim 2  wherein said weld is a tig weld. 
   
   
       4 . The method according to  claim 3  wherein said shower pan has a recessed area in said base around said opening such that when said drain is positioned in said opening a top surface of said drain is in generally the same plane as the top surface of an area of said base around said opening. 
   
   
       5 . The method according to  claim 4  wherein said floor drain is comprised of a unitary structure having a flange surrounding a top surface of said drain, said top surface having a reservoir thereunder and a drain pipe extending from said reservoir. 
   
   
       6 . The method according to  claim 5  wherein said drain has a plurality of weep holes in said top surface. 
   
   
       7 . The method according to  claim 6  wherein said drain has a top surface with a flange extending horizontally therefrom, a sidewall extending from an underside of said top surface, said sidewall having a first end and a second end, said first end being connected to the underside of said top surface, said second end being connected to a base of said reservoir said base of said reservoir having a drain pipe extending therefrom. 
   
   
       8 . The method according to  claim 7  wherein said top surface of said drain has an opening therein, said opening having a sidewall extending into said reservoir. 
   
   
       9 . The method according to  claim 8  wherein said sidewall of said opening is threaded. 
   
   
       10 . A unitary shower pan and drain comprising
 a drain, said drain having a top surface with a flange extending horizontally therefrom, a sidewall extending from an underside of said top surface, said sidewall having a first end and a second end, said first end being connected to the underside of said top surface, said second end being connected to a base of said reservoir said base of said reservoir having a drain pipe extending therefrom;   a shower pan, said shower pan fabricated from a sheet of sheet metal having a length and a width, said shower pan having a base and one or more sidewalls extending upwardly from said base, said base having an opening therein and a recessed area surrounding said opening said drain being received in said recessed area, said drain having been welded to said base such that a top surface of said drain is in generally the same plane as the top surface of the base of said shower pan adjacent to said recessed area in said base.   
   
   
       11 . The unitary shower pan and drain according to  claim 10  wherein said sheet metal is stainless steel. 
   
   
       12 . The unitary shower pan and drain according to  claim 11  wherein said weld is a tig weld. 
   
   
       13 . The unitary shower pan and drain according to  claim 12  wherein said drain has a plurality of weep holes in said top surface. 
   
   
       14 . The unitary shower pan and drain according to  claim 13  wherein said top surface of said drain has an opening therein said opening having a sidewall extending into said reservoir. 
   
   
       15 . The unitary shower pan and drain according to  claim 14  wherein said sidewall of said opening is threaded. 
   
   
       16 . A one-piece drain comprising
 a top surface, said top surface having a flange extending horizontally therefrom, said top surface of said drain having an orifice therein;   a reservoir, said reservoir having a sidewall extending from an underside of said top surface, said sidewall having a first end and a second end, said first end being connected to the underside of said top surface, said second end being connected to the base of said reservoir, said base having an orifice therein;   a drain pipe, said drain pipe having a sidewall extending from the base of the reservoir surrounding said orifice in said base.   
   
   
       17 . A one-piece drain according to  claim 16  wherein said orifice in said top surface has a sidewall extending into said reservoir. 
   
   
       18 . A one-piece drain according to  claim 17  wherein said sidewall of said orifice in said top surface is threaded. 
   
   
       19 . A one-piece drain according to  claim 18  wherein said drain has a plurality of weep holes in said top surface. 
   
   
       20 . A mortar guard to protect weep holes on a top surface of a drain, said mortar guard comprising a top surface, a bottom surface and at least one side wall extending from said top surface to said bottom surface. 
   
   
       21 . The mortar according to  claim 20  wherein said mortar guard is comprised of a filament nylon fiber so that water may pass through the surface of said mortar guard to said drain. 
   
   
       22 . The mortar guard according to  claim 21  wherein said fiber is a continuous filament nylon fiber. 
   
   
       23 . The mortar guard according to  claim 22  wherein said top surface has an orifice therein, said orifice extending from said top surface to said bottom surface. 
   
   
       24 . A shower base comprising
 a floor drain, said floor drain having a top surface with a flange extending horizontally therefrom, a sidewall extending from an underside of said top surface, said sidewall having a first end and a second end, said first end being connected to the underside of said top surface, said second end being connected to a base of said reservoir said base of said reservoir having a drain pipe extending therefrom;   a shower pan, said shower pan fabricated from a sheet of sheet metal having a length and a width, said shower pan having a base and one or more sidewalls extending upwardly from said base, said base having an opening therein and a recessed area surrounding said opening said floor drain being received in said recessed area, said floor drain having been welded to said base such that a top surface of said drain is in generally the same plane as the top surface of the base of said shower pan adjacent to said recessed area in said base;   a mortar guard to protect weep holes on a top surface of a drain, said mortar guard comprising a top surface, a bottom surface and a side wall extending from said top surface to said bottom surface, said mortar guard comprising a nylon fiber material so water may pass through the surface of said mortar guard to said drain;   a finish coat applied above the shower pan, floor drain and mortar guard, said finish coat having mortar.   
   
   
       25 . The shower base according to  claim 24  wherein said finish coat includes tile. 
   
   
       26 . The shower base according to  claim 25  wherein said finish coat includes stone. 
   
   
       27 . A shower base according to  claim 24  further comprising a drainage mat, said drainage mat being placed between the mortar and the shower pan, said drainage mat being able to support the weight of the finish coat and fabricated from a generally flat sheet of a plastic material, said drainage mat generally sized to fit the shower pan. 
   
   
       28 . A drainage mat according to  claim 27  wherein said drainage mat has a plurality of channels. 
   
   
       29 . A shower base according to  claim 27  further comprising a shower drain, said shower drain having a top surface, said top surface having an orifice, said top surface having one or more sidewalls surrounding said orifice, said sidewalls extending downward from the underside of said top surface, said top surface having sidewalls extending upward from said top surface, said top surface having two or more elevated surfaces, said elevated surfaces having one or more recesses for receiving a screw. 
   
   
       30 . A shower base according to  claim 29  further comprising a shower grate, said grate having a surface, said surface sized to fit in the top surface of said shower drain, said surface having first type and second type of orifice, said first type of orifice is sized for receiving a screw, said second type of orifices is sized for water permeability. 
   
   
       31 . A shower grate according to  claim 30  wherein the shape of said top surface of said shower grate is round. 
   
   
       32 . A shower grate according to  claim 30  wherein the shape of said top surface of said shower grate is square.