Manufactured Shower Pan

Abstract

A manufactured shower pan includes a drain, a molded waterproof liner having a properly sloped floor and extending side walls, a honeycomb liner support, a solid curb system and a processed dry mud pack to provide aeration and drainage connected to the weep system in the drain.

Description

RELATED APPLICATIONS

[0001] This application claims priority from copending U.S. provisional patent application 60/928,007 filed May 7, 2007.

FIELD OF THE INVENTIONS

[0002] The inventions described below relate to the field of construction and more specifically to the field manufactured shower pans.

BACKGROUND OF THE INVENTIONS

[0003] Historically shower pan installation required several days to accomplish and depended on the skill of the craftsmen to not leak. The decrease in skill in the construction trades and the pressure to cut costs are making manufactured showers and pans more attractive. However, conventional manufactured showers and shower pans are either too flexible for ceramic tiles to remain attached over time or do not provide sufficient drainage beneath the tile and mold and fungus flourish.

SUMMARY

[0004] A manufactured shower pan includes a drain, a molded waterproof liner having a properly sloped floor and extending side walls, a honeycomb liner support, a curb system and a processed dry mud pack to provide aeration and drainage connected to the weep system in the drain.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a cross section view of a manufactured shower pan.

[0006] FIG. 2A is a top view of a solid shower curb.

[0007] FIG. 2B is a cross section of the solid shower curb of FIG. 2A taken along A-A.

[0008] FIG. 3A is a top view of a sloped shower liner support.

[0009] FIG. 3B is a cross section of the sloped shower liner support of FIG. 3A taken along B-B.

[0010] FIG. 4A is a top view of a shower liner.

[0011] FIG. 4B is a cross section of the shower liner of FIG. 4A taken along C-C.

[0012] FIG. 5 is a cross section view of a manufactured shower pan with tiles and sewer line attached.

[0013] FIG. 6 is a cross section view of a manufactured shower pan with a dual side curb.

[0014] FIG. 7A is a top view of the dual side curb and shower pan liner of the manufactured shower pan of FIG. 6.

[0015] FIG. 7B is a cross section of the dual side curb and shower pan liner of FIG. 7A taken along D-D.

DETAILED DESCRIPTION OF THE INVENTIONS

[0016] A manufactured shower pan 10 as illustrated in FIG. 1 includes a solid or unitary curb 12 to support and contain sloped pan support 14. Together, curb 12 and pan support 14, support pan liner 15 which is the waterproof liner that includes drain connection 16 that extends through floor 18. Pan liner 15 supports and contains mud pack 20. Mud pack 20 may be secured to the pan liner during manufacturing or installed in the field.

[0017] Curb 12 is illustrated in FIGS. 2A and 2B. Curb 12 is composed of three or more sides such as sides 21 that are ideally formed together as any suitable polygon enclosing the shower floor. Shape 12F of the shower floor may adopt any suitable size and shape. In an alternate configuration, curb 12 may be formed of separate side elements that may simplify manufacturing and shipping. The separate side elements may include complementary engagement elements at each end to engage adjacent curb sides. Curb 12 may only be used on one side of the waterproof liner and the remaining two or more sides of the polygon may be vertical to blend into a vertical shower wall. Generally, the curb and the pan liner will be square or generally rectangular.

[0018] Pan support 14 is illustrated in FIGS. 3A and 3B. Pan support 14 provides sufficiently rigid support to pan liner 15 to enable attachment of ceramic tiles to pan liner 15 and the pan support will prevent flexing of the pan liner which will crack and dislodge the ceramic tiles or other surface covering. Pan support 14 may be used to compensate for a floor that is not level and also includes slope 22 to permit drainage of water in the shower pan. Slope 22 affords drainage to drain opening 24. Support 14 is shown composed of numerous adjacent hexagonal cells such as cell 26 to form a honeycomb lattice or pattern to provide lightweight, and rigid support for pan liner 15. Any other support configuration may be used such as cylinders, open or closed cell foam, such as a rectangular or triangular lattice or any other configuration. Pan support 14 may be produced as a separate element as discussed, or it may be formed as an integral element of pan liner 15. Alternatively, pan support 14 may be secured to pan liner 15 during manufacturing using any suitable technique such heat or sonic welding, adhesives or co molding.

[0019] Pan liner 15 is a waterproof element as shown in FIGS. 4A and 4B. The shape of floor 15F corresponds to shape 12F of curb 12. Drain connection 16 is integral with pan liner 15 to prevent leakage. Lower drain connection 16L may be a slip connection to a drain pipe or may be threaded. Drain connection 16 also includes weep paths 27 for conducting moisture from mud pack 20 into the drain pipe. Floor 15F of a pan liner such as pan liner 15 includes slope 28 corresponding to support slope 22.

[0020] Curb shape 12S may alternatively be formed into pan liner 15 creating curb space 15C. Curb space 15C may be filled during manufacturing or during field installation with any suitable material such as high density expanding foam, PVC foams or other suitable fillers.

[0021] Mud pack 20 is a dry, generally planar element sized and sloped to fit within liner floor 15F and provide a substrate for attachment of ceramic tiles. Mud pack 20 provides a path for water absorbed through tile grout and thin set used to attach ceramic tiles to pass into drain 16.

[0022] Referring now to FIG. 5, shower pan 30 may be installed by setting curb 31 in a desired location such as a shower site and securing it to floor 32 and or any adjacent walls. A plumber should have already located a drain pipe such as drain pipe 33 at or near the center of the shower site to be occupied by shower pan 30. Pan support 34 is then located within curb 31 and drain pipe 33 should be visible through drain access 34D. Pan support 34 may be secured to floor 32 and or curb 31 for additional stability using any suitable technique such as fasteners or adhesive. Pan liner 35 is placed to cover curb 31 and pan support 34 with drain connector 35D engaging drain pipe 33. Pan liner 35 may be secured to curb 31 and pan support 34 for additional stability using any suitable technique such as fasteners or adhesive. Mud pack 36 is then located within the floor of pan liner 35. The preceding steps may all be performed within a single day and upon securing mud pack 36 to the pan liner, any suitable surface covering such as stone, slate and or tiles such as tiles 37 may be set in the shower pan and the shower walls. This technique permits a shower pan to be set and tiled in a single day.

[0023] The drain connector 35D has been discussed as centered in pan liner 35. Any suitable orientation of the drain connection may be used as long as the pan liner is formed with the drain connection in the predetermined location.

[0024] Alternate shower pan 40 of FIGS. 6, 7A and 7B is constructed as discussed above with curb space 42 extending along only two sides, sides 43 and 45 of the shower floor 40F and an integral pan support and factory installed mud pack. One or more sides of a shower pan will include a curb or curb space. Curb space 42 is filled at the factory with a high density form. Pan liner sides 46, 47, 48 and 49 are not engaging a curb or including a curb space and are vertical to engage a vertical shower wall and enable tile from the shower wall to extend in a generally unbroken plane to the shower floor. In this configuration, pan liner 44 is a six-sided polygon enclosing shower floor 40F.

[0025] Installation of alternate shower pan 40 may be accomplished by locating pan 40 with drain connector 40D engaging drain 54. Pan 40 may be secured to floor 53 and pan liner sides 46, 47, 48 and 49 may be secured to walls such as wall 51. If curb space 42 is filled at the factory and mud pack 52 is installed at the factory, pan 40 will be ready to support installation of tile or stone or other surface covering.

[0026] While the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Other embodiments and configurations may be devised without departing from the spirit of the inventions and the scope of the appended claims.

Claims

1. A manufactured shower pan comprising: a curb forming one or more sides of a generally horizontal polygon, the polygon oriented to enclose a drain; a honeycomb liner support within the curb providing vertical support and drainage slope for a molded waterproof liner; a molded waterproof liner resting on the honeycomb liner support forming a waterproof floor and sides with suitable drainage slope and a connection to the drain, the connection including a weep system; and a processed dry mud pack engaging the molded waterproof liner to provide aeration and drainage connected to the weep system in the connection to the drain.

2. The manufactured shower pan of claim 1 wherein the curb forms two sides of a rectangular polygon enclosing a drain.

3. The manufactured shower pan of claim 1 wherein the curb is formed of high density foam injected into a curb space in the pan liner.

4. The manufactured shower pan of claim 1 wherein the honeycomb liner support is formed together with the pan liner as one piece.

5. A manufactured shower pan for engaging a drain through a floor, comprising: a rectangular curb secured to the floor enclosing a shower floor including the drain; a support frame within the rectangular curb, the support frame having a drain access port for exposing the drain; a pan liner forming a waterproof layer over the rectangular curb and the support frame, the pan liner having a drain connector for connecting to the drain; and a mud pack secured within the pan liner.

6. The manufactured shower pan of claim 5 wherein the support frame comprises: a honeycomb lattice support frame within the rectangular curb, the support frame having a drain access port for exposing the drain.

7. The manufactured shower pan of claim 5 wherein the support frame comprises: a circle pattern lattice support frame within the rectangular curb, the support frame having a drain access port for exposing the drain.

8. The manufactured shower pan of claim 5 wherein the support frame comprises: a rectangular lattice support frame within the rectangular curb, the support frame having a drain access port for exposing the drain.

9. A method of installing a manufactured shower pan in a shower site containing a drain comprising the steps: securing a curb on one or more sides of the shower site; securing a pan support within the shower site adjacent the curb; and locating a pan liner having a drain connector and a mud pack over the curb and the pan support with the drain connector engaging the drain.

10. The method of claim 9 wherein the step of locating a pan liner further comprises the steps: locating a pan liner having a drain connector over the curb and the pan support with the drain connector engaging the drain; and securing a mud pack within the pan liner.