U.S. patent application number 14/182447 was filed with the patent office on 2014-08-21 for waterproof base with composite shower curb, and methods of fabrication and installation thereof.
This patent application is currently assigned to DAVIS INTELLECTUAL ASSETS, LLC. The applicant listed for this patent is DAVIS INTELLECTUAL ASSETS, LLC. Invention is credited to Thomas A. DAVIS, JR..
Application Number | 20140230140 14/182447 |
Document ID | / |
Family ID | 51350023 |
Filed Date | 2014-08-21 |
United States Patent
Application |
20140230140 |
Kind Code |
A1 |
DAVIS, JR.; Thomas A. |
August 21, 2014 |
WATERPROOF BASE WITH COMPOSITE SHOWER CURB, AND METHODS OF
FABRICATION AND INSTALLATION THEREOF
Abstract
A tile-ready shower base system including a composite curb, and
methods of manufacturing and installing the same. A sloped
structural core is provided having a top side and a bottom side. A
first waterproof panel or coating is applied to the top side and a
second waterproof panel or coating is applied to the bottom side. A
thin fiberglass flange is provided about at least a portion of the
perimeter of the core to create a lip. The basin further includes a
first hole or recess formed into the basin, which does not extend
through the basin, and a second hole, axially aligned with the
first, which does extend through the basin, for directly receiving
and coupling a drain therein. The composite curb is provided along
at least one side of the basin. Optionally, a compressible soft
material or cushioned layer can be applied over the first
waterproof panel of the sloped structural core.
Inventors: |
DAVIS, JR.; Thomas A.;
(Savannah, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DAVIS INTELLECTUAL ASSETS, LLC |
SAVANNAH |
GA |
US |
|
|
Assignee: |
DAVIS INTELLECTUAL ASSETS,
LLC
SAVANNAH
GA
|
Family ID: |
51350023 |
Appl. No.: |
14/182447 |
Filed: |
February 18, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61766315 |
Feb 19, 2013 |
|
|
|
61766319 |
Feb 19, 2013 |
|
|
|
61861049 |
Aug 1, 2013 |
|
|
|
Current U.S.
Class: |
4/613 ; 29/428;
29/525.01 |
Current CPC
Class: |
A47K 3/40 20130101; Y10T
29/49826 20150115; Y10T 29/49947 20150115; E03F 5/0409 20130101;
E03F 5/0408 20130101 |
Class at
Publication: |
4/613 ; 29/428;
29/525.01 |
International
Class: |
A47K 3/40 20060101
A47K003/40 |
Claims
1. A waterproof shower base system comprising: an expanded polymer
core defining a top surface and a bottom surface, the top surface
sloping toward a drain opening extending through the polymer core
from the top surface to the bottom surface, and further comprising
a drain receiving recess in the top surface and extending at least
partially through the expanded polymer core surrounding the drain
opening; a waterproof top layer applied over the top surface of the
expanded polymer core; a bottom skin applied to the bottom surface
of the expanded polymer core at least around the drain opening; an
upright flange projecting above the top surface of the expanded
polymer core about at least a portion of the periphery of the
expanded polymer core; and a curb along at least one side of the
expanded polymer core, the curb comprising a base portion and a
high-density anchoring cap portion, the base portion comprising a
lightweight expanded foam body defining a height and a width, and
the high-density anchoring cap portion comprising a fastener
retaining material and having a width substantially matching the
width of the base portion, the high-density anchoring cap portion
being substantially permanently attached to the lightweight
expanded foam body of the base portion.
2. The waterproof shower base system of claim 1, wherein the
upright flange has a thickness of no more than 0.25 inches.
3. The waterproof shower base system of claim 1, wherein the
waterproof top layer comprises a fiberglass mesh and epoxy
resin.
4. The waterproof shower base system of claim 1, further comprising
an elastomeric waterproofing layer applied to at least a portion of
its exposed exterior surfaces.
5. The waterproof shower base system of claim 1, wherein drain
receiving recess defines an annular surface directed toward the top
surface forming a clamping surface for engagement with a portion of
the tile drain.
6. The waterproof shower base system of claim 1, wherein the
lightweight expanded foam body of the curb comprises a closed-cell
foam.
7. The waterproof shower base system of claim 6, wherein the
closed-cell foam comprises expanded polystyrene.
8. The waterproof shower base system of claim 1, wherein the
high-density anchoring cap portion comprises a material selected
from polyethylene, polyvinylchloride, polypropylene,
acrylonitrile-butadiene-styrene, fiberboard, foamed PVC board, foam
backer board and combinations thereof.
9. The waterproof shower base system of claim 1, further comprising
a sealant applied over external surfaces of at least the base
portion.
10. The waterproof shower base system of claim 9, wherein the
sealant is compatible with a thinset adhesive grout.
11. The waterproof shower base system of claim 1, further
comprising at least one fastener for retention by the high-density
anchoring cap portion.
12. The waterproof shower base system of claim 1, further
comprising a cushioning layer overlying the waterproof top
layer.
13. The waterproof shower base system of claim 12, wherein the
cushioning layer comprises ethylene-vinyl acetate foam.
14. The waterproof shower base system of claim 12, further
comprising a slip resistant cap layer overlying the cushioning
layer.
15. A method of fabricating a shower base system, said method
comprising: forming an expanded polymer core to define a top
surface and a bottom surface, the top surface sloping toward a
drain opening extending through the polymer core from the top
surface to the bottom surface, and further comprising a drain
receiving recess in the top surface and extending at least
partially through the expanded polymer core surrounding the drain
opening; applying a waterproof top layer over the top surface of
the expanded polymer core; applying a bottom skin to the bottom
surface of the expanded polymer core at least around the drain
opening; and installing a composite curb along at least one side of
the expanded polymer core.
16. The fabrication method of claim 15, further comprising
attaching an upright flange projecting above the top surface of the
expanded polymer core about at least a portion of the periphery of
the expanded polymer core.
17. The fabrication method of claim 16, wherein the upright flange
has a thickness of no more than 0.25 inches.
18. The fabrication method of claim 15, wherein the step of
applying a waterproof top layer comprises applying a fiberglass
mesh and epoxy resin to the top surface of the expanded polymer
core.
19. The fabrication method of claim 15, further comprising applying
a compressible soft material layer over the waterproof top layer
secured to the top surface of the expanded polymer core.
20. The fabrication method of claim 15, further comprising applying
an elastomeric waterproofing layer to at least a portion of the
shower base's exposed exterior surfaces.
21. The fabrication method of claim 15, further comprising forming
an annular surface of the drain receiving recess directed toward
the top surface to define a drain clamping surface.
22. The fabrication method of claim 15, wherein the composite curb
comprises a base portion and a high-density anchoring cap portion,
the base portion comprising a lightweight expanded foam body
defining a height and a width, and the high-density anchoring cap
portion comprising a fastener retaining material and having a width
substantially matching the width of the base portion, the
high-density anchoring cap portion being substantially permanently
attached to the lightweight expanded foam body of the base
portion.
23. The fabrication method of claim 15, further comprising
installing a sealing material across the interface between the
expanded polymer core and the composite curb.
24. The fabrication method of claim 15, further comprising
installing tile over at least a portion of the composite curb.
25. The fabrication method of claim 15, further comprising mounting
a structural component to the composite curb by at least one
fastener retained by the high-density anchoring cap portion.
26. A method of installing a waterproof shower base, said method
comprising: providing an assembly comprising an expanded polymer
core defining a top surface and a bottom surface, the top surface
sloping toward a drain opening extending through the polymer core
from the top surface to the bottom surface, and further comprising
a drain receiving recess in the top surface and extending at least
partially through the expanded polymer core surrounding the drain
opening, said drain receiving recess defining an annular surface
directed toward the top surface to define an upper drain clamping
surface, the assembly further comprising a waterproof top layer
applied over the top surface of the expanded polymer core, and a
bottom skin applied to the bottom surface of the expanded polymer
core at least around the drain opening; placement of the assembly
onto a substrate, with the drain opening aligned with a lower drain
element in the substrate; attaching an upper drain element against
the drain clamping surface of the drain receiving recess of the
assembly and in engagement with the lower drain element; and
installing a composite shower curb base along at least one side of
the expanded polymer core.
27. The installation method of claim 26, wherein the step of
placement of the assembly onto a substrate further comprises
applying a thin-set mortar between the substrate and the
assembly.
28. The installation method of claim 26, wherein the assembly
further comprises a thin flange surrounding at least a portion of
the expanded polymer core, and wherein a tile backer-board is
installed overlying at least a portion of the thin flange.
29. The installation method of claim 26, further comprising
installing an adjustable drain top onto the upper drain
element.
30. The installation method of claim 26, further comprising
leveling the assembly on the substrate.
31. The installation method of claim 26, further comprising
applying a silicone caulk between the lower drain element and the
assembly.
32. The installation method of claim 26, further comprising
applying a thin-set mortar over the upper drain element within the
drain receiving recess.
33. The installation method of claim 26, further comprising
applying tile over the waterproof top layer of the assembly.
34. The installation method of claim 26, further comprising
applying a compressible soft material layer over the waterproof top
layer of the assembly.
35. The installation method of claim 26, wherein the step of
providing the assembly comprises determining at least one dimension
of the substrate and having the assembly custom fabricated based on
the determined at least one dimension of the substrate.
36. A cushioned drainage floor assembly comprising: a sloped core,
the sloped core comprising a top, a bottom, at least one sidewall,
and a drain opening extending therethrough; and a cushioning layer
overlying the top of the sloped core.
37. The cushioned drainage floor assembly of claim 36, wherein the
cushioning layer comprises an opening substantially aligned with
the drain hole of the sloped core.
38. The cushioned drainage floor assembly of claim 36, further
comprising a substantially vertically oriented flange secured to at
least a portion of the perimeter of the sloped core to create a
lip.
39. The cushioned drainage floor assembly of claim 36, wherein the
sloped core comprises a foam material.
40. The cushioned drainage floor assembly of claim 36, comprising
an expanded polystyrene core and an ethylene-vinyl acetate foam
cushioning layer.
41. The cushioned drainage floor assembly of claim 40, further
comprising a slip resistant cap layer.
42. The cushioned drainage floor assembly of claim 40, further
comprising an epoxy mesh bottom skin.
43. The cushioned drainage floor assembly of claim 36, further
comprising a perimeter flange.
44. A method of installing a drainage floor, said method
comprising: preparing a subfloor surface; applying a closed-cell
foam core over the prepared subfloor surface; and applying a
compressible soft material layer over the closed-cell foam
core.
45. The method of claim 44, further comprising installing a drain
through a drain opening through the compressible soft material
layer and the closed-cell foam core.
46. The method of claim 44, further comprising installing a
perimeter flange around at least a portion of the closed-cell foam
core.
47. The method of claim 44, further comprising installing a curb
around at least a portion of the closed-cell foam core.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/766,315 filed Feb. 19, 2013; U.S.
Provisional Patent Application Ser. No. 61/766,319 filed Feb. 19,
2013; and U.S. Provisional Patent Application Ser. No. 61/861,049
filed Aug. 1, 2013, the entireties of which are hereby incorporated
by reference herein.
TECHNICAL FIELD
[0002] The present invention relates generally to waterproof bases,
curbs and shower pan inserts or drainage floor assemblies for
shower stalls and the like, and more particularly to pre-made
custom shower bases, curbs and inserts, and methods of fabrication
and installation thereof.
BACKGROUND
[0003] Generally, there are two types of shower stalls, pre-made
and custom fabricated stalls. Custom fabricated stalls are often
utilized for home renovations when it is difficult to transport
large building materials through home doorways. Custom fabricated
stalls are also used for installations not having a "typical" or
industry standard sized shower area. These stalls are often tiled
for decorative and aesthetic appeal. Typically, when constructing a
custom tiled shower stall, the stall area is pre-fitted with a
waterproof liner, shower pan, or other water impermeable surface to
prevent water from leaking from the stall. Generally, the
decorative tiles are then set in mortar over the liner to form the
interior wall of the stall. However, tiled shower stalls are known
to leak for a variety of reasons.
[0004] One such reason for shower stall leaks stems from damage to
the waterproof shower liner or membrane. For example, a hole or
tear in the liner can occur during the installation of the tile,
which can require an installer to start all over in constructing
the custom shower stall. Other leaks occur from damage to the
shower pan or liner caused by the settling of the house. Regardless
of how the leaks are born, significant damage can occur to the
structure of the house as a result of the water leaks. Such damage
can be costly and time consuming to correct.
[0005] Another problem with existing custom shower stalls is the
difficulty in connecting the water drain of a shower stall to a
drainpipe in the floor of the house. Presently, custom-built shower
basins typically utilize specialized drain plumbing to connect the
two, which results in additional plumbing work, installation time,
and cost.
[0006] Shower systems and drainage floor assemblies commonly
utilize a raised curb or threshold to limit the spread of water
across a floor area. Traditionally, a shower curb was formed from a
wood base structure with tile or other water-resistant surface
material applied thereon. Over time, however, water may migrate
through the surface material and into the wood base. This commonly
causes the wood base to swell, resulting in cracks in the tile or
other surface material, and rotting of the wood base material.
Water migration is all the more likely if anchors for mounting or
supporting a shower partition or shower door are driven through the
water-resistant surface material into the base material, which
forms a penetration pathway for leakage.
[0007] Other base materials such as concrete, expanded foam blocks,
and solid plastic blocks or synthetic wood products have been
utilized for fabricating a shower curb, but have not been found
fully satisfactory. Concrete cores are time consuming and expensive
to produce, heavy and therefore not well suited to transport from a
remote fabrication facility to a jobsite, and require special tools
to drill and drive anchors into for mounting partitions or shower
doors. Expanded foam blocks typically lack sufficient holding
strength to retain anchors for mounting partitions or shower doors,
and their exterior surface may not be compatible for adhesion by
grout to apply a tile surface thereon. Solid plastic blocks or
synthetic wood products can also be undesirably heavy and
expensive.
[0008] Furthermore, the decorative tiles or other walking surfaces
or flooring in bathrooms and showers are typically wet and
slippery, which commonly cause slips and falls, sometimes leading
to injuries. The flooring in such areas is commonly sloped for
drainage, and often uses hard and unforgiving surface materials,
often increasing the likelihood of a fall and/or the likelihood of
sustaining an injury from a fall.
[0009] Thus it can be seen that needs exist for improvements to
custom-built shower bases to prevent water from leaking from the
shower stall in combination with an improved base structure for
forming a shower curb and an improved shower pan insert. It can
also be seen that needs exist for shower bases that allow a direct,
reliable and universal connection between the shower drain and the
interior plumbing of a house, in combination with an improved base
structure including a composite shower curb assembly and an
improved shower pan insert. It is to the provision of an improved
shower base with composite curb and an improved shower pan or
drainage floor assembly meeting these and other needs that the
present invention is primarily directed.
SUMMARY
[0010] The shower base of the present invention can be used for
both residential and commercial tile shower applications. The
shower base can be used in place of typical known sloped liner and
mortar tile shower bases. A curb is provided along at least one
side of the shower base. Each shower base can be manufactured to
the exact specifications of a user's shower stall area as
determined by a user or installer, including the location of the
user's drain. The shower base is manufactured via a process by
which the base has a substantially greater waterproofing ability
than with known shower bases.
[0011] In one aspect, the present invention relates to a waterproof
base providing connection between a tile drain and a drainpipe. The
shower base includes an expanded polymer core defining a top
surface and a bottom surface, the top surface sloping toward a
drain opening extending through the polymer core from the top
surface to the bottom surface, and further comprising a drain
receiving recess in the top surface and extending at least
partially through the expanded polymer core surrounding the drain
opening. The shower base also includes a waterproof top layer
applied over the top surface of the expanded polymer core, and a
bottom skin applied to the bottom surface of the expanded polymer
core at least around the drain opening.
[0012] In example forms, the shower base also includes a curb along
at least one side of the expanded polymer core. The curb includes a
base portion and a high-density anchoring cap portion, the base
portion including a lightweight expanded foam body defining a
height and a width, and the high-density anchoring cap portion
including a fastener retaining material and having a width
substantially matching the width of the base portion, the
high-density anchoring cap portion being substantially permanently
attached to the lightweight expanded foam body of the base portion.
In one form, the lightweight expanded foam body includes a
closed-cell foam having expanded polystyrene. The high-density
anchoring cap portion can include a material selected from
polyethylene, polyvinylchloride, polypropylene,
acrylonitrile-butadiene-styrene, fiberboard, foamed PVC board, foam
backer board and combinations thereof. Optionally, a sealant is
applied over external surfaces of at least the base portion.
Preferably, the sealant is compatible with a thinset adhesive
grout. Further optional, at least one fastener is included for
retention by the high-density anchoring cap portion.
[0013] In another aspect, the invention is a method of fabricating
a shower base. The method preferably includes the step of forming
an expanded polymer core to define a top surface and a bottom
surface, the top surface sloping toward a drain opening extending
through the polymer core from the top surface to the bottom
surface, and further including a drain receiving recess in the top
surface and extending at least partially through the expanded
polymer core surrounding the drain opening. The method preferably
also includes applying a waterproof top layer over the top surface
of the expanded polymer core, and applying a bottom skin to the
bottom surface of the expanded polymer core at least around the
drain opening.
[0014] In example forms, the fabrication method also includes
installing a composite curb along at least one side of the expanded
polymer core. The composite curb includes a base portion and a
high-density anchoring cap portion, the base portion including a
lightweight expanded foam body defining a height and a width, and
the high-density anchoring cap portion including a fastener
retaining material and having a width substantially matching the
width of the base portion, the high-density anchoring cap portion
being substantially permanently attached to the lightweight
expanded foam body of the base portion. In one form, the
fabrication method also includes installing a sealing material
across the interface between the expanded polymer core and the
composite curb. The fabrication method further includes installing
tile over at least a portion of the composite curb. The fabrication
method also includes mounting a structural component to the
composite curb by at least one fastener retained by the
high-density anchoring cap portion.
[0015] In another aspect, the invention is a method of installing a
waterproof base. The method preferably includes the step of
providing an assembly comprising an expanded polymer core defining
a top surface and a bottom surface, the top surface sloping toward
a drain opening extending through the polymer core from the top
surface to the bottom surface, and further including a drain
receiving recess in the top surface and extending at least
partially through the expanded polymer core surrounding the drain
opening. The drain receiving recess preferably defines an annular
surface directed toward the top surface to define an upper drain
clamping surface. The assembly preferably further includes a
waterproof top layer applied over the top surface of the expanded
polymer core, and a bottom skin applied to the bottom surface of
the expanded polymer core at least around the drain opening. The
method preferably further includes placement of the assembly onto a
substrate, with the drain opening aligned with a lower drain
element in the substrate, and attaching an upper drain element
against the drain clamping surface of the drain receiving recess of
the assembly and in engagement with the lower drain element. The
method preferably further includes installation of a composite
shower curb core along at least one side of the shower base, and
installing tile or other surface covering material(s) over the base
and curb to form an integrated shower containment system.
[0016] In another aspect, the present invention relates to a
cushioned shower pan or drainage floor assembly for use in a
shower, bathroom or other area from which water or other liquids
are to drain. The cushioned shower pan or drainage floor assembly
can be used with or in place of known sloped shower base assemblies
with tile or other hard surface materials. The cushioned shower pan
or drainage floor assembly can be manufactured in standard sizes,
and/or manufactured to the exact specifications of a user's shower
or bathroom area as determined by a user or installer, including
the location of the user's drain, the shower dimensions, the slope,
thickness, degree of resilience, etc.
[0017] In example forms, the present invention relates to a
cushioned drainage assembly, also referred to as a shower base,
shower pan insert or drainage floor panel. The cushioned drainage
assembly generally includes an expanded poly-styrene (EPS) or other
substantially rigid foam core having a surface sloped toward a
drain or drain opening formed through the foam core, and a
resilient cushioning surface layer of foam, rubber, neoprene or
other soft water-resistant material(s), laminated or otherwise
attached to the sloped core. The sloped core generally includes a
top side, a bottom side and a drain hole. The cushioning layer
attaches to the top side of the sloped core. Optionally, an upright
perimeter flange may be secured around all or a portion of the
perimeter of the drainage assembly.
[0018] In another aspect, the invention relates to cushioned
drainage floor assembly including a closed-cell foam core and a
compressible soft material layer applied over the closed-cell foam
core.
[0019] In still another aspect, the invention relates to method of
installing a drainage floor, the method including preparing a
subfloor surface, applying a closed-cell foam core over the
prepared subfloor surface, and applying a compressible soft
material layer over the closed-cell foam core.
[0020] These and other aspects, features and advantages of the
invention will be understood with reference to the drawing figures
and detailed description herein, and will be realized by means of
the various elements and combinations particularly pointed out in
the appended claims. It is to be understood that both the foregoing
general description and the following brief description of the
drawings and detailed description of the invention are exemplary
and explanatory of preferred embodiments of the invention, and are
not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is a side view of a shower base with a curb
according to an example embodiment of the present invention.
[0022] FIG. 1B is a close up view of the several layers comprising
the shower base of FIG. 1A.
[0023] FIG. 2 is a side cross-sectional view of the shower base
with the curb of FIG. 1A.
[0024] FIG. 2A is a detailed cross-sectional view of the threshold
area of the shower curb and base assembly of FIG. 2, over which
tile or other surface material can be applied.
[0025] FIG. 3 is a side cross-sectional view of the curb of FIGS.
1A and 2.
[0026] FIG. 3A is a perspective view of the curb of FIG. 3.
[0027] FIG. 3B is a perspective view of a shower area including a
shower basin, a shower curb, and a shower enclosure mounted to the
curb according to another example embodiment of the present
invention.
[0028] FIG. 4 is a perspective view of the drain hole of the shower
base of FIG. 1.
[0029] FIG. 5 is a perspective view of the drain hole of FIG. 4,
shown with a shower drain mounted therein.
[0030] FIG. 6 is a perspective view of the drain hole of FIG. 4,
shown with another shower drain mounted therein.
[0031] FIG. 7A is a side view showing further detail of the drain
connection for the shower base of FIG. 1.
[0032] FIG. 7B is a close up view of the drain connection area of
FIG. 7A.
[0033] FIGS. 8-10 show a sequence of installation of the shower
base according to an example form of the present invention.
[0034] FIG. 11 is a side view of a cushioned shower base according
to another example embodiment of the present invention.
[0035] FIG. 11A is a close up view of the drain connection area of
FIG. 11.
[0036] FIG. 11B is an exploded view of the drain of FIG. 11A.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0037] The present invention may be understood more readily by
reference to the following detailed description of the invention
taken in connection with the accompanying drawing figures, which
form a part of this disclosure. It is to be understood that this
invention is not limited to the specific devices, methods,
conditions or parameters described and/or shown herein, and that
the terminology used herein is for the purpose of describing
particular embodiments by way of example only and is not intended
to be limiting of the claimed invention. Any and all patents and
other publications identified in this specification are
incorporated by reference as though fully set forth herein.
[0038] Also, as used in the specification including the appended
claims, the singular forms "a," "an," and "the" include the plural,
and reference to a particular numerical value includes at least
that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment.
[0039] With reference now to the drawing figures, FIGS. 1A and 1B
show a "tile-ready" shower base 10 according to an example
embodiment of the present invention. The shower base 10 of the
present invention can be used for both residential and commercial
tile shower applications. The shower base 10 can be used in place
of typical known sloped liner and mortar tile shower bases. Each
shower base 10 can be custom manufactured to the exact
specifications of a user's shower stall area as determined by a
user or installer, including the location of the user's drain, or
can be fabricated in one or more standard size formats. The shower
base 10 is manufactured via a fabrication process and installed via
an installation process, each discussed herein, by which the base
has a substantially greater waterproofing ability than previously
known shower bases. In example forms, the shower base 10 generally
comprises a sloped basin 20, at least one drain 30, and a raised
curb or threshold 40.
[0040] The shower basin 20 is fabricated as an assembly 60 of
multiple layers, as shown in greater detail in FIG. 1B, which are
coupled together into a unitary component through a unique
manufacturing process that creates an exceptionally strong and long
lasting waterproof surface. The assembly is preferably
factory-fabricated, and delivered to a remote installation site for
installation. When fully constructed, the basin has a graded slope
towards the drain 30. It is preferred that the minimum amount of
slope is about 0.25 inches/foot, but other slopes can be utilized
as desired by a user.
[0041] In example embodiments, a core layer 62 of the basin 20 is
formed from expanded polystyrene foam, polypropylene structural
honeycomb thermoplastic, foam, rubber, plastics, wood, metals, or
other solid or porous formable structural material(s). The core 62
is contoured to accommodate the desired slope of the basin. The
core 62 is sandwiched between two waterproof panels or sheets 64,
66 of acrylic, thermoplastic, or other waterproof panel materials
such as for example, PLAS-TEX.RTM. (manufactured by Parkland
Plastics), CORIAN.RTM., or POLYCOMP.RTM.. In an example embodiment,
the waterproof top layer is a fiberglass mesh and epoxy resin top
coat 64, and the waterproof bottom layer is a waterproof skin
applied around the drain area. An adhesive such as for example,
GORILLA GLUE.RTM., is preferably applied between the waterproof
panels 64, 66 and the core 62; and a membrane press, or other
pressure applying method or apparatus, can be used to press the
panels and core together. The assembly resulting from the
combination of the waterproof panels 64, 66 and the core 62 is
referred to as the sloped sandwiched blank ("SSB") 68.
[0042] Once the SSB 68 is completed, a layer of crack isolation
material 70 is optionally applied to the sloped (top) surface of
the SSB to prevent and/or contain any cracks that may develop in
the SSB 68. In example embodiments, the crack isolation material 70
comprises a polyester, such as the material sold under the
tradename FLEX-GUARD.RTM.. The crack isolation material 70 allows
for expansion and contraction between the SSB 68 and the material
(typically tile) applied over the SSB. In alternate example
embodiments, as will be described below, a cushion layer can
optionally be applied over the SSB 68.
[0043] After application of the crack isolation material 70, the
SSB 68 receives a fiberglass/PLAS-TEX.RTM. flange 72 that surrounds
the perimeter of the SSB. In example embodiments, the flange 72 is
about 5 inches in height, but the height of the flange can vary as
desired. It is preferred that the flange 72 be secured to the SSB
68 with silicone adhesive, although other types of adhesives can be
applied. After the flange 72 has been secured to the SSB 68, the
exterior of the basin 20 is encapsulated with fiberglass cloth and
saturated with polyester fiberglass resin. Optionally, a bead joint
of adhesive is applied to the joint between the flange 72 and SSB
68 for further waterproofing. The flange 72 is preferably thin, for
example about 0.25'' or less, to permit the shower's tile wall
backerboard to extend over the flange to the sloped top surface of
the shower base, for leak prevention and ease of installation. Once
installed in the appropriate location, the basin 20 is ready to
receive tile. U.S. Pat. No. 8,181,288 is incorporated herein by
reference.
[0044] As seen in FIGS. 1A, 2 and 3, the curb 40 is applied to the
basin 20. Typically, the curb 40 is positioned along the length of
the entry point for a user to enter the basin area, or otherwise
positioned along at least a portion of the periphery of the basin
20, which may result in it being positioned along two or more sides
of the basin 20. Generally, the curb 40 is a composite body
comprising a core or base portion 42 and a cap or anchoring portion
44. The base portion 42 and the anchoring portion 44 are attached
to one another by adhesive, solvent welding, laminating, or other
substantially permanent attachment means. The curb 40 is
manufactured in a similar process as the basin 20, except that the
curb typically includes a much thicker core 42, as seen in the
drawing figures. The curb 40 preferably comprises a generally
rectangular prismatic body having a generally square or rectangular
cross-sectional profile of, for example, about 4'' wide by about
4'' high, and can be fabricated in various stock lengths and/or cut
to custom length for a particular application. In alternate
embodiments, the dimensions of the curb may vary depending on the
intended application.
[0045] The base portion 42 of the curb 40 comprises an expanded
polystyrene (EPS) closed-cell foam material or other lightweight
and water-resistant or waterproof material. In alternate forms, the
base portion 42 can comprise other expanded synthetic materials
having an open or closed cell configuration. The base portion 42
preferably comprises a generally rectangular prismatic body having
a generally rectangular cross-sectional profile of, for example,
about 4'' wide by about 31/2'' high.
[0046] The anchoring cap portion 44 of the curb is formed from a
high-density plastic material, such as for example polyethylene
(HDPE), polyvinylchloride (PVC), polypropylene (PP),
acrylonitrile-butadiene-styrene (ABS), fiberboard, foamed PVC
board, foam backer board, or other water-resistant or waterproof
material having sufficient hardness and density to resist pull-out
of a screw or other anchor and to support the load of a typical
shower door or enclosure panel. The anchoring cap portion 44 can be
formed as a solid or hollow body having a cross-sectional profile
of, for example, about 4'' wide by about 1/2'' high, the width of
the anchoring cap portion 44 preferably substantially matching the
width of the base portion 42 such that their side edges align when
assembled and form an integral body having a substantially
continuous external surface.
[0047] The base portion 42 and the anchoring cap portion 44 can be
secured together by adhesives, glues, fasteners, or the like.
Optionally, mounting hardware or other elements may be embedded
within the anchoring cap 44 and/or the base 42 wherein
interengaging fasteners may be provided to secure a shower
enclosure or other supported structure 52 thereto (as will be
described below). A water-resistant or waterproof coating or
sealant layer may optionally be applied over the curb 40, such as
for example an elastomeric membrane acrylic coating, or a
latex-based waterproof paint or coating, to which thin-set or other
adhesive or mortar will adhere.
[0048] Optionally, the curb 40 supports a shower door, enclosure
panel or other structure 52, and one or more fasteners 50 secure
the structure to the curb (see FIGS. 1A, 3B). The anchoring cap
portion 44 of the curb 40 is positioned at the top of the base
portion 42 so that the fasteners 50 securing the shower enclosure
52 thereto engage and fasten into the anchoring portion 44.
[0049] FIG. 2 shows a cross-sectional view of the curb 40 installed
with the shower base 10. An adhesive layer of polymer modified
thin-set or construction mastic is applied onto the subfloor to
secure the curb 40 and shower base 10 in position. A polyurethane
sealant 46 is optionally applied between the curb 40 and the shower
base 10. Further, an additional sealing layer is optionally
provided over the interface between the shower base 10 and the curb
40 by applying a reinforcing fabric 47 along adjacent surfaces
thereof. The shower base 10 and the curb 40 can then be covered
with tile or other decorative surface materials and a shower
enclosure or other structure 52 can be mounted by one or more
fasteners to the anchoring member 44 of the curb 40.
[0050] FIG. 3B shows further detail of the curb 40 of the present
invention installed around a shower basin 20, and covered with a
decorative surface material (e.g., tile, acrylic sheet, cushion
layer, etc.). As such, the shower enclosure 52 is secured to the
curb 40 wherein the fasteners 50 engage an anchoring system (e.g.,
hardware) of the shower enclosure 52 and further extend through the
decorative layer and into the anchoring cap 44 to secure the shower
enclosure 52 to the curb 40.
[0051] In example embodiments, the basin 20 includes a first drain
hole or recess 22 in the top surface of the basin to receive a
standard tile drain 30 during installation, as seen in FIGS. 4-10.
The drain recess 22 is about six inches in diameter, although the
diameter of the recess can vary as desired or needed to accommodate
a particular drain 30. The recess 22 preferably extends from the
top surface of the basin 20 through the top waterproof layer 64 and
at least partially through the EPS core 62, but not through the
bottom waterproof layer or skin 66. A second drain hole 24 is
axially aligned with the first hole or drain recess 22 and extends
through the SSB 68 in its entirety, including through the bottom
waterproof layer or skin 66. The second drain hole 24 is preferably
about four inches in diameter, but can vary depending on the
application. The recess and drain hole 22, 24 allow a clamping
attachment mechanism 80 of a standard tile drain 30 to be used to
couple the basin 20 to a drain body 82 installed in the sub-floor
and connected to a standard interior or exterior plumbing
drainpipe, as depicted in FIGS. 5-9D.
[0052] The shower base 10 is installed by cleaning and removing any
debris from the sub-floor in the area that the shower base is to be
installed. Latex modified thin-set mortar is applied to the
substrate using a square or U-notched trowel (thin-set should be
flush with the top edge of the drain body flange). A bead of 100%
silicone adhesive is applied around the outside perimeter area of
the tile drain body 82 to provide a watertight seal (see FIG. 9).
The shower base 10 is lowered into place, and the shower base is
solidly embedded in the mortar, and leveled to insure proper
drainage. Optionally, an impermeable layer (e.g., ShowerSeal.TM.)
can be added above the thin-set prior to the installation of the
shower base 10. Drain bolts are replaced, the clamping ring 80
installed, and the drain clamp bolts tightened to engage the bottom
skin 66 of the shower base in the area of the recess 22. The drain
top 30 is adjusted to the desired height, and latex modified
thin-set is troweled into the area around the clamping ring 80. The
shower base 10 is then ready to be tiled according to typical
fashion. Because the basin 20 is directly coupled to the drain body
82, a watertight seal can readily be relied upon without the need
for additional plumbing work, which is typically necessary with
pre-made shower bases. Additionally, the shower base of the present
invention enables use of a standard tile drain, without need for
specialized parts or modification.
[0053] In additional example embodiments and as briefly described
above, the shower base 10 can be in the form of a cushioned shower
pan or drainage floor assembly 100, which generally comprises the
shower base 10 as described above covered with a cushion layer 110,
for example, by being laminated, adhered or otherwise attached to
an exposed or top surface of the sloped core 120 or the SSB 168. In
one form, as depicted in FIG. 11, the cushioned shower pan 100
generally comprises the cushioned EVA foam backing layer 110, a
sloped EPS basin or core 120, a drain opening 122, an optional curb
140, and an optional perimeter flange 172. Preferably, a drain 130
is installed to create a watertight seal with a drain body 135
(e.g., 2'' IPS pipe) that is installed below the sub-floor. As
depicted in FIG. 11A, the cushioned shower pan or drainage floor
assembly 100 may optionally comprise a plurality of additional
layers (e.g., skins, backings, seals, caps, etc.) in addition to
the cushioned layer 110 and the core 120. For example, in example
embodiments and as similarly described above, an epoxy/mesh bottom
skin 166 and an epoxy/mesh top skin 164 are applied to the sides of
the EPS core 162 (forming the SSB 168), the cushioned layer 110 is
applied to the epoxy/mesh top skin 164. Optionally, a pliable
material or decorative/slip resistant EVA foam cap layer 112 can be
applied to the cushioned layer 110.
[0054] Generally, the cushioned layer 110 substantially covers the
entire sloped (top) surface of the shower base 100 and can
optionally be attached to the exposed surfaces of the curb 140. In
one example form, the cushion layer 110 is formed from
ethylene-vinyl acetate (EVA) foam or other resilient
water-resistant or waterproof material. In alternate forms, the
cushion layer 110 can be formed from various other materials
including closed cell foam, latex, neoprene, rubber, compressible
plastics or other resilient natural or synthetic materials
exhibiting flexibility, dampening and/or cushioning. In example
forms, the cushion layer 110 provides a resilient surface for
increased grip and comfort, and for dampening or injury-reducing
effect to substantially reduce the likelihood of injury due to
accidentally falling or slipping thereon. In example embodiments,
the cushioned layer 110 may be applied and attached to the SSB 168
at a manufacturing facility and delivered to the job site as a
ready to install assembly; or alternatively can be applied and
attached at the jobsite, either before or after installation of the
core onto the shower subfloor.
[0055] In example methods of use, the cushioned shower pan or
drainage floor assembly 100 can be installed by troweling an
adhesive layer of polymer modified thin-set or construction mastic
to the sub-floor area where the cushioned shower pan 100 is to be
installed. Optionally, the impermeable layer (e.g., ShowerSeal.TM.)
can be added above the thin-set prior to the installation of the
sloped basin 120. The sloped basin 120 is then installed over the
thin-set and/or the impermeable layer. The drain 130 is installed
and attached through the drain opening 122, for example as shown in
FIG. 11B, to provide a watertight seal with the sloped basin. A
caulk or silicone sealant may optionally be applied around the
perimeter of the drain 130 to provide a watertight seal.
[0056] The present invention therefore includes a tile-ready shower
base apparatus 10 and a cushioned shower pan apparatus 100, both of
which do not have many of the problems typically associated with a
tiled shower basin, a method of manufacturing or fabricating such
apparatus, and a method of installing such apparatus. While the
invention has been described with reference to preferred and
example embodiments, it will be understood by those skilled in the
art that a variety of modifications, additions and deletions are
within the scope of the invention, as defined by the following
claims.
* * * * *