Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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IMPROVEMENTS IN MODULAR SHOWER ENCLOSURES
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[0001]
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to prefabricated leak-proof
shower modules
and, more particularly, to various manufacturing and installation methods, and
to resulting
articles.
[0004] 2. Description of the Prior Art
[0005] Most tile-covered shower enclosures are created using complicated
construction
methods. For example, using conventional techniques, a skilled installer
frames out the area to
be enclosed using two-by-four wooden or aluminum studs to create a frame and
curb. Felt or tar
paper is then laid over a subfloor area enclosed within the newly formed
frame. A flexible, leak-
proof liner is installed on top of the felt or tar paper and attached to the
frame. Next, the installer
attaches dry wall boards to the framing studs, creating shower sidewalls. A
hole is cut in the
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liner to allow for a drain, and a layer of mortar is applied to the shower
sidewalls and curb and
allowed to cure. Additional mortar is applied on top of the leak-proof liner
and hand-shaped to
form a shower floor which slopes toward the drain such that water from the
shower flows toward
the drain. After the mortar has cured, shower tile is applied to the sidewalls
and floor to create
the finished enclosure.
[0006] The process of creating the enclosed shower is time-consuming and
requires a certain
degree of skill in order to maintain the proper pitch and uniformity in
shaping the floor.
Irregularities in the pitch of the floor can cause water from the shower not
to drain properly or
make tiling the shower enclosure difficult. The liners are also susceptible to
punctures or leaks
and may be difficult for the installer to properly form square corners at the
intersection of the
shower sidewalls and floor. Additionally, the mortar layer used to create the
floor is necessarily
thick in order to form a sloped surface, therefore the time required for the
floor to cure before
applying tile may be quite long (e.g., greater than 24 hours).
[0007] In recent years, the process of shower installation has been vastly
improved by the
introduction of prefabricated shower base modules used for forming the floor.
Use of the
prefabricated modules significantly decreases the amount of time and skill
required to construct a
tile-covered shower enclosure, as well as providing more of a consistent and
reliable= flooring
surface upon which to tile. These modules are pre-constructed molded units
having a sloping
floor, an integrated drain, curb, sidewalls, and a horizontal surface on the
top of each sidewall for
mounting drywall such that the drywall is substantially flush to the module
sidewalls.
Installation of the module involves securing a section of drain pipe to the
drain, applying
adhesive and sealing material to the subfloor where the module will rest, and
seating the module
on the subfloor. Tile can then be applied directly to the shower walls and
module without the
need for first applying mortar.
[0008] However, these prefabricated shower modules contain weaknesses in
the design
which add cost to the final product. For instance, certain modules are
manufactured using
plastics-forming processes that inject molten polymeric resins into molds.
After filling the mold
with the resin, the module must cool (e.g., solidify) before being removed. If
the module is
removed before it is completely solid, bowing may occur as the module hardens.
However, the
mold or "tool" for creating each unit can be quite expensive, thus a
manufacturer generally limits
the number of tools for producing each module. Therefore, the number of
modules manufactured
in a given amount of time depends on the amount of time required for one
module to sufficiently
cool enough to be removed from the mold.
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[0009] Because the mold is 'needed to create other modules, the
manufacturer is pressed to
fmd ways to decrease the required cooling time. This problem is exacerbated by
non-uniform
thicknesses of the plastic material throughout the module. Cooling rates for
thick areas of the
module are slower than for thinner areas. Thus, if the module is removed from
the mold before it
is completely cooled, areas of the modules having different thicknesses cool
at different rates,
resulting in bowing across the surface of the floor As a result, severely
bowed modules must be
discarded, increasing the unit cost for other modules. Additionally, slightly
bowed modules
present potential field problems (i) by impacting uniform tile adhesion on the
upper surface of
the floor of the shower module, (ii) by preventing the lower surface of the
floor of the shower
module from sitting flush on the subfloor, and (iii) by changing the pitch of
the upper floor of the
shower module, which causes puddling or ponding of water on the upper floor of
the shower
module rather than properly pitched draining. Further, uneven cooling along
the drain aperture
may result in a misshapen aperture, thereby (i) preventing the installer from
acquiring (or
hampering his/her ability to acquire) a water-tight seal around the drain
fixture, and (ii)
interfering with the insertion of the drain fixture into the drain aperture.
Uneven cooling along
the drain assembly (i) may prevent a proper connection (e.g., a water-tight
connection) between
the drain assembly and the shower module, (ii) may warp the drain aperture at
the top of the
drain assembly, thereby interfering with the insertion of the drain top intol
the top of drain
assembly, and (iii) may warp the drain aperture in the bottom of the drain
assembly, thereby
interfering with the connection of the drain assembly to the plumbing line.
[0010] Further, each size module requires a specific mold, thus the
manufacturer is forced to
limit the selection of available modules to a few standard sizes. Because the
curb may be
integrated into the shower module, both the positioning of the curb, as well
as the overall
dimensions of the module are set by a single tool. The design options for a
customer (e.g., an
architect, a designer, a contractor, an installer, or homeowner) desiring to
implement a
prefabricated shower module are therefore limited to a few set arrangements.
[0011] Additionally, features such as shower benches or ledges must still
be constructed by
hand, or added in a piece-meal fashion, thereby compromising the leak-proof
integrity of the
prefabricated shower module.
[0012] Therefore, a need exists for, among other things, a ribbed,
prefabricated, leak-proof
polyurethane shower module for use in constructing a tiled shower enclosure
and having surfaces
suitable for receiving shower tile, marble or stone thereon to overcome the
shortcomings of the
prior art.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a top plan view of a prefabricated shower module in
accordance with one
embodiment of the present invention.
[0014] FIG. 2 is a side cross-sectional elevational view of the
prefabricated shower module
of FIG. 1 along the line 2-2.
[0015] FIG. 3 is a bottom plan view of the prefabricated shower module of
FIG.1, illustrating
a horizontal support rib arrangement.
.100161 FIG. 4 is a front/top perspective view of the shower module of FIG.
1.
[0017] FIG. 4A is a front/top perspective view of a shower module in
accordance with an
alternative embodiment of the present invention.
[0018] FIG. 4B is a front/top perspective view of a shower module in
accordance with
another alternative embodiment of the present invention.
[0019] FIG. 5 is a cross-sectional view of a prior art shower module drain
assembly.
[0020] FIG. 6 is a cross-sectional view of an exemplary drain assembly, in
accordance with
an embodiment of the present invention.
[0021] FIG. 7 is a bottom plan view of a prefabricated shower module,
illustrating an
exemplary sunburst support rib arrangement, in accordance with an alternative
embodiment of
the present invention.
[0022] FIG. 8 is a bottom plan view of a prefabricated shower module,
illustrating an
exemplary diamond support rib arrangement, in accordance with an alternative
embodiment of
the present invention.
[0023] FIG. 9 is a bottom plan view of a prefabricated shower module,
illustrating an
exemplary honeycomb support rib arrangement, in accordance with another
alternative
embodiment of the present invention.
[0024] FIG. 10 is a front/top perspective view of a prefabricated shower
module having pre-
scored indentations for attaching a modular curb along any sidewall, in
accordance with another
= alternative embodiment of the present invention.
[0025] FIG. 11 is a front/top perspective view of a handicapped-accessible
prefabricated
shower module in accordance with an alternative embodiment of the present
invention.
= [0026] FIG. 12 is a front/top perspective, view of a handicapped-
accessible prefabricated
shower module in accordance with another alternative embodiment of the present
invention.
[0027] FIG. 13 is a front elevational view of the prefabricated shower
module of FIG. 11.
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[0028] FIG. 14 is a front/top perspective view of a prefabricated shower
module having an
integrated curb, in accordance with another alternative embodiment of the
present invention.
[0029] FIG. 15 is a front/top perspective view of a prefabricated shower
module having an
integrated curb, in accordance with another alternative embodiment of the
present invention.
[0030] FIG. 16 is a cross-sectional view of the prefabricated shower module
of FIG,. 15 along
the line 16-16.
[0031] FIGs. 17-18 are logic flow diagrams of various steps executed to
implement a method
for manufacturing an improved, prefabricated leak-proof shower module, in
accordance with
exemplary embodiments of the present invention.
[0032] FIG. 19 is a front/top perspective view of a prior art modular curb.
[0033] FIG. 20 is a front/top perspective view of a prefabricated modular
curb in accordance
with one embodiment of the present invention.
[0034] FIG. 21 is a front/bottom perspective view of a prefabricated
modular curb in
accordance with one embodiment of the present invention.
[0035] FIG. 22 is a side/top perspective view illustrating an exemplary
installation of the
modular curb of FIG. 21 with the shower module of FIG. 1.
[0036] FIG. 23 is a side/top perspective view illustrating an exemplary
installation of an
alternative embodiment of a modular curb in accordance with an exemplary
embodiment of the
present invention. =
[0037] FIG. 24 is a front/bottom perspective view of a prefabricated
modular curb in
accordance with an alternative embodiment of the present invention.
[0038] FIG. 24A is a side cross-sectional view illustrating an exemplary
installation of an
alternative embodiment of a modular curb in accordance with an exemplary
embodiment of the
present invention.
[0039] FIGs. 25-27 are logic flow diagrams of various steps executed to
implement a method
for creating a tiled shower stall using a prefabricated leak-proof shower
module and- a
prefabricated modular curb, in accordance with exemplary embodiments of the
present invention.
[0040] FIG. 28 is a front/top perspective view of a prefabricated shower
seat in accordance
with an embodiment of the present invention.
[0041] FIG. 29 is a front/top perspective view of a prefabricated shower
seat in accordance
with an alternative embodiment of the present invention.
[0042] FIG. 30 is a side elevational view illustrating an exemplary
installation of the
prefabricated shower seat of FIG. 28 installed with a prefabricated shower
module of FIG. 1, in
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accordance with an embodiment of the present invention.
[0043] FIG. 31 is a logic flow diagram of various steps executed to
implement a method for
creating a tiled shower stall using a prefabricated leak-proof shower module
and a prefabricated
shower seat, in accordance with exemplary embodiments of the present
invention.
[0044] FIG. 32 is a front/top perspective view of a complete shower
enclosure system
constructed using a prefabricated shower module, a prefabricated modular curb,
and a
prefabricated shower bench, in accordance with exemplary embodiments of the
present
invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)
[0045] Before describing in detail exemplary embodiments that are in
accordance with the
present invention, it should be observed that the embodiments reside primarily
in combinations
of apparatus components and processing steps related to implementing a method
for improving
manufacturability of a pre-molded leak-proof shower module having surfaces for
receiving
shower tile or stone thereon and the associated shower module. Accordingly,
the apparatus and
method components have been represented where appropriate by conventional
symbols in the
drawings, showing only those specific details that are pertinent to
understanding the
embodiments of the present invention so as not to obscure the disclosure with
details that will be
readily apparent to those of ordinary skill in the art having the benefit of
the description herein.
[0046] In this document, relational terms, such as "first" and "second,"
"top" and "bottom,"
and the like, may be used solely to distinguish one entity or element from
another entity or
element without necessarily requiring or implying any physical or logical
relationship or order
between such entities or elements. The terms "comprises," "comprising," or any
other variation
thereof are intended to cover a non-exclusive inclusion, such that a process,
method, article, or
apparatus that comprises a list of elements does not include only those
elements, but may include
other elements not expressly listed or inherent to such process, method,
article, or apparatus. The
term "plurality of" as used in connection with any object or action means two
or more of such
object or action. A claim element proceeded by the article "a" or "an" does
not, without more
constraints, preclude the existence of additional identical elements in the
process, method, article,
or apparatus that includes the element. The term "tile" also encompasses
"stone" and/or
"marble." The term "tiled" means any surface having tile, stone, and/or marble
applied thereon.
The term "sidewall," in relation to a shower module, means any vertical
surface rising above the
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floor of the shower module along one or more peripheral edges and may be any
height or any
width, including, without limitation, an integrated curb.
[0047] Generally, the present invention encompasses a prefabricated modular
system for
constructing a tiled shower enclosure; an improved prefabricated shower
module, modular curb,
and shower seat for use within the system, and methods for manufacturing and
installing the
above components.
[0048] In a preferred embodiment, a prefabricated leak-proof shower module
suitable for use
in constructing a tiled shower includes a plurality of sidewalls, and a floor
that is bounded along
at least one peripheral edge by at least one sidewall that extends vertically
from the peripheral
edge. The floor has an upper surface sloping downward from each peripheral
edge toward a
drain aperture and a lower surface with a plurality of support ribs, where
each support rib extends
downward from the lower surface to terminate in a common horizontal plane.
Additionally, the
upper surface may contain a plurality of pitching ribs which provide a uniform
pitch from each
peripheral edge to the drain aperture. Each support rib runs and each pitching
rib runs either
parallel to, perpendicular to, or at an acute angle to, at least one
peripheral edge of the floor. The
shower module may be created using polyurethane reaction injection molding
processing.
Alternative embodiments may include a horizontal bottom plane and/or an
integrated molded
curb.
[0049] In another embodiment, a prefabricated modular curb suitable for use
in constructing
a tiled shower enclosure includes a mounting wall with an outer surface for
engaging a sidewall
of a shower module, an exterior wall, and a top wall that extends from an
upper edge of the
exterior wall to the upper edge of the mounting wall in a plane either
substantially perpendicular
to the mounting wall and to the exterior wall or pitching downward from the
exterior wall to the
mounting wall. The curb further includes at least one reinforcing curb rib
that is attached to at
least one of the top curb wall, the inner surface of the mounting wall, the
inner .surface of the
exterior wall, and the bottom wall if any, and which rib runs either parallel
to, perpendicular to,
or at an acute angle to the mounting wall or the exterior wall.
[0050] In another embodiment, a prefabricated shower bench for installation
in a tiled shower
includes a seating surface having a plurality of peripheral edges, and at
least three sidewalls,
wherein each sidewall is connected to a corresponding peripheral edge of the
seating along an
upper edge. One of the sidewalls includes a setback area along its entire
lower, edge that has a
height greater than the height of one of the sidewalls of a prefabricated
shower module. The
lower edge of each sidewall terminates in a common plane.
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[0051] 1. Prefabricated Shower Module
[0052] The present invention can be more readily understood with reference
to FIGs. 1-32, in
which like reference numerals designate like items. FIGs. 1-4 depict an
exemplary prefabricated
leak-proof shower, module 100 suitable for use in constructing a tiled shower
in accordance with
one embodiment of the present invention. As depicted in FIGs. 1-4, the
exemplary shower
module 100 includes a floor 110, and vertical sidewalls 101, 102, 103, 104 (4
shown). The upper
surface 112 of the floor 110 and the vertical sidewalls 101, 102, 103, 104 are
suitable for
retaining tile, stone, or marble installed thereon. Each sidewall 101, 102,
103, 104 extends
vertically from a peripheral edge of the floor 110. The floor 110 has an upper
surface 112 that
slopes downward from each peripheral edge toward a drain aperture 130, and a
lower surface 114
that connects to a plurality of support ribs 120. The upper surface 112 slopes
downward from
each peripheral edge to the drain aperture 130 at a pitch of 1/8"/foot or
greater.
[0053] Each support rib 120 extends downward from the lower surface 114
such that the
bottom edge 122 of each support rib 120 terminates in a common horizontal
plane. Additionally,
each support rib 120 runs either parallel to, perpendicular to, or at an acute
angle to, at least one
peripheral edge of the floor 110. When the shower module 100 is installed to
construct a shower
enclosure, the shower module 100 is positioned on a subfloor of the shower
enclosure in such a
manner that the plurality of support ribs 120 provide support for the shower
module 110 by
resting on the subfloor, and a drain wall 132 surrounding the drain aperture
130 is positioned
inside or above an opening in the subfloor that contains a plumbing
connection.
[0054] In an alternative embodiment, as shown in FIG. 4A, the shower module
700 includes
a bottom panel 160 that extends from each sidewall 101, 102, 103, 104 and/or
each peripheral
edge to the drain wall 132 in a horizontal plane. Thus, the bottom panel 160
rests on the subfloor
of the shower enclosure when the shower module 100 has been installed.
Additionally, the
bottom edge 122 of each support rib 120 is connected to the bottom panel 160.
[0055] In another alternative embodiment, as shown in FIG. 4B, the shower
module 800
includes a floor 110 that extends in a horizontal plane from each sidewall
101, 102, 103, 104
and/or peripheral edge to a drain wall 132 surrounding the drain aperture 130.
Pitching ribs 121
extend upwards from the upper surface 112 and terminate in an upper edge
sloping downwards
from the peripheral edge to the drain aperture 130.
[0056] In one embodiment, at least one sidewall 104 has a height that is
lower than the height
of the remaining sidewalls 101, 102, 103. The height of the lower sidewall 104
is preferably at
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least one inch lower than the height of the remaining sidewalls 101, 102, 103.
The lowered
height insures that in the event that the plumbing connection becomes clogged,
any standing
water in the shower module 100 will spill over onto the floor of the bathroom
in which the
shower enclosure is constructed instead of seeping into the walls; preventing
water damage or
mold accumulation. Additionally, the top surface of any sidewall 101, 102,
103, 104 should
either be flat or pitched towards the shower module 100 so that any water
accumulating on the
top surface flows back into the shower module 100.
100571 The height of the lower sidewall 104 is preferably sufficient to
permit installation of a
modular curb 300 (see FIG. 21) adjacent to the sidewall 104. The lower
sidewall 104 may be
initially molded to the required height, molded to the same height as the
other sidewall 101, 102,
103 and trimmed as a part of post-production process, or may contain a
horizontal fatigue line
108 (see FIG. 10) located at a height suitable for a portion of the sidewall
104 to be removed,
thereby allowing installation of a modular curb adjacent to the sidewall. The
horizontal fatigue
line 108 denotes a thinner section of the sidewall 104 and can be easily
broken, or cut, and
removed. The fatigue line 108 may be molded into the sidewall during an
injection molding
process, or pre-scored by the manufacturer. The fatigue line 108 may be
included on any or all
of the sidewalls 101, 102, 103, 104 so that an installer may have the option
of choosing a
sidewall 101, 102, 103, 104 for attaching the prefabricated modular curb 300.
After installation
of tile on the surface of the shower module 100, any inherent weakness in a
sidewall 101, 102,
103, 104 still containing a horizontal fatigue line 108 does not affect the
integrity of the shower
enclosure and is obscured by the tile.
[0058] In an alternative embodiment, the outer surface of the lower
sidewall 104 may include
an attachment mechanism 106 (see FIG. 23) for engaging a corresponding
attachment
mechanism 316 of a modular curb 300. Exemplary methods for attaching the
modular curb 300
to the shower module 100 are discussed in greater detail in Section 2. The
attachment
mechanism 106 may be a tab, a notch, a slot, a tongue, a groove, a ridge, a m,
an aperture, an
interlocking clip, an adhesive material, or any other mechanism suitable for
connecting the
modular curb 300 to the shower module 100.
[0059] In one embodiment of the present invention, the shower module 100 is
constructed
using polyurethane reaction injection molded processes. When using injection-
molding
techniques, the shower module 100 may be molded from a polymeric material such
as
polyurethane foam having a density equal to or greater than 12 pounds per
cubic foot. A lower
density polyurethane material would be, most likely, unable to support a
connection to the drain.
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[0060] The overall thickness of the material, as well as variances in the
thickness of material
used, has a substantial impact on the quality of the shower module 100, 700,
800. During
manufacturing, the shower module 100, 700, 800 is formed by injecting a liquid
polymeric
material into a tool having a core and a cavity, which define the shape of the
finished shower
module 100, 700, 800. The core and cavity of the tool, when fastened together,
form a hollowed
area that corresponds to the fmal shower module 100, 700, 800. As the
polymeric material cools,
it conforms to the shape defined by the tool and solidifies into the final
shower module 100, 700,
800. The thickness of the material affects the cooling rate of the fmished
product. Thicker
sections cool at a slower rate than thinner sections. If a shower module 100,
700, 800 contains
sections having an uneven thickness, the thinner sections will cool much more
quickly than the
thick sections, which may cause the upper surface and the lower surface of the
shower module
100, 700, 800 to bow or warp,
[0061] The area surrounding the drain aperture 130 is of particular
importance in the cooling
process. In the drain area in previous prefabricated shower modules, such as
the drain area
shown in FIG. 5, the drain wall was maintained at a constant diameter below
the bottom floor of
the shower module, but smaller than the plumbing opening in the shower
enclosure subfloor. The
rational for shaping the drain wall in this fashion was that the constant
diameter would provide a
more secure fit, and would support the drain. However, by maintaining a
constant outer diameter
of the drain wall, the thickness of the drain wall surrounding the drain
aperture or the drain
assembly varies as the depth of the drain wall increases from the top of the
drain aperture or drain
assembly to the bottom of the drain aperture or drain assembly, because the
diameter of the drain
aperture or drain assembly at the top of the drain aperture or drain assembly
is larger than the
diameter at the bottom. Because of the difference in material thickness in the
drain wall, the
thinner areas cooled faster than the thicker areas.
100621 This cooling differential resulted in bowing and warping in one or
more of the upper
surface in the vicinity of the drain wall, the lower surface in the vicinity
of the drain wall, the
drain aperture, the drain assembly, and the drain aperture inside the drain
assembly, thereby (i)
causing problems with the pitch of the upper surface, (ii) impacting tile
adhesion to the upper
surface, (iii) impacting the water tightness of the seal between the drain
fixture (not shown) and
the drain aperture at or around the upper surface, the drain fixture and the
drain aperture at or
around the lower surface, and the drain fixture and the inside of the drain
aperture, (iv) impacting
whether the lower surface of the shower module is level around the drain wall,
(v) impacting the
top and bottom shape of the drain aperture thereby interfering with the
insertion of a drain fixture
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into the drain aperture, and (vi) impacting the shape of the drain aperture
inside the drain
assembly thereby interfering with the connection of the drain assembly to the
plumbing line and
the insertion of the drain top into the drain assembly.
[0063] As shown in FIG. 2, a drain may be attached to the shower module
100, 700, 800 at
the drain aperture 130 in one of two methods. The shower module 100, 700, 800
may be molded
with a prefabricated drain assembly 134 integrated into the shower module
floor 110 and encased
inside the drain wall 132, or with a drain fixture 135 affixed to the shower
module 100 after
fabrication of the shower module 100 by inserting the drain fixture 135 into
the drain aperture
130 molded into the shower module floor 110 and drain wall 132. When the drain
fixture 135 is
attached to the shower module 100 subsequent to fabrication, a water-tight
seal must be
established between the drain fixture 135 and the shower module 100 at one or
more of the drain
aperture 130, the upper surface 112, and the lower surface 114, to prevent
leaking.
[0064] In an embodiment of the present invention, as shown in FIG. 6, the
drain wall 132
surrounding the drain assembly 134 or the drain aperture 130 has a thickness
that is contoured to
approximate variances in the diameter of the drain assembly 134 or the drain
fixture 135. The top
of the drain aperture 130 and the drain assembly 134 may have a greater
diameter than the
bottom of the drain aperture 130 and the drain assembly 134, because the top
portion of most
drain fixtures and drain assemblies is wider where the water drains from the
floor 110 of the
shower module 100 into the drain assembly 134 or the drain fixture 135, than
at the bottom
portion of the drain fixture 135 and/or the drain assembly 134 where they
connect to the
plumbing line. Accordingly, the upper portion of the drain wall 132 may have a
greater diameter
than the lower portion of the drain wall 132, as the drain wall 132 is
contoured to more closely
and uniformly follow the diameter of the respective portions of the either
drain assembly 134 or
the drain aperture 130 used to connect a drain fixture 135.
[0065] The largest diameter of the drain wall 132 at the thickest part of
the drain wall 132 is
equal to or less than 4 times the diameter of the drain aperture 130 at the
bottom of the drain
wall. 130. The thickness of the bottom of the drain wall 132 measured from the
outside wall of
the bottom of the drain wall 132 to the drain aperture 130 at the bottom of
the drain wall 132 is
equal to or less than 11/2 times the diameter of the drain aperture at the
bottom of the drain wall.
130. The actual thickness of the drain wall 132, the thickness of the shower
module floor 110 at
the drain wall 132, the diameter of the drain wall 132, and the contour of the
drain wall 132, will
vary depending upon the size of the drain, the weight of the drain, the size
of the drain aperture,
and whether the drain is made of one or more of PVC, ABS, brass, copper, iron,
or other metal.
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By adhering to the above guidelines, most instances of bowing or warping of
the shower module
floor 110, the drain wall 132, the drain assembly 134, and the drain aperture
130 may be
significantly reduced.
[0066] If a prefabricated drain assembly 134 is integrated into the shower
module floor 110,
the prefabricated drain assembly 134 is inserted into the tool prior to
injecting the polymeric
material. A drain reinforcing structure 136, which has an opening in the
center with a diameter
that is slightly smaller than the outer diameter of the drain assembly 134, is
placed over the drain
assembly 134 in such a manner that edges of an interior diameter of the drain
reinforcing
structure 136 interfere with the outer diameter of the prefabricated drain
assembly 134. The
drain assembly 134 with the attached drain reinforcing structure 136 is then
placed inside the tool
such that it lies in a horizontal plane in an intermediary position between
the cavity and the core
of the tool. The polymeric material surrounds the drain assembly 134 and the
drain reinforcing
structure 136 when injected into the tool, thereby permanently embedding the
drain assembly 134
with the attached drain reinforcing structure 136 within the floor 110 of the
shower module 100
and integrating the prefabricated drain assembly 134 within the shower module
100. The
prefabricated drain assembly 134 may be any PVC, ABS, brass, copper, iron, or
metal drain
assembly designed to be coupled with any standard sized drain pipe. The drain
reinforcing
structure 136 may be mesh, solid, or porous, and made from wire, metal,
fiberglass, plastic,
polymers, or any combination of the foregoing. The density, thickness, size
and shape of the
drain reinforcing structure 136 will vary depending on the size, weight, drain
aperture, and
material of the drain assembly 134.
[0067] Both the prefabricated drain assembly 134 and the drain fixture 135
subsequently
attached to the drain aperture 130 may contain a male drain top which is
inserted into a female
drain either by pushing down or screwing down the male drain top into the
female drain top. The
male drain top may also be connected to a detachable drain screen 138 covering
an aperture in
the center of the male drain top. The detachable drain screen 138 may have the
form of any
geometric shape (e.g., circular, oval, square, rectangular, diamond, etc.).
'When the shower
module 100, 700, 800 has been covered by tile, the male drain top with the
drain screen 138
attached may either rest slightly below the surface of the tile or be
substantially flush with the
tile. Upon installation, the tile is cut to conform to the shape of the
detachable drain screen 138.
The male drain top is lowered to the height of the tile or just below the tile
height, and then the
detachable drain screen 138 is attached to the top of the drain in a manner to
conform to the drain
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screen shape formed by the installed tile. The height of the male drain top
may be adjusted for
use with tile of any thickness.
100681 Any bowing or warping of the shower module 100, 700, 800, the drain
aperture 130,
or the drain assembly 134 creates problems in (i) attempting to properly seal
the connection
between the drain fixture 135 or the drain assembly 134 and the drain wall
132, (ii) attempting to
adhere the tiles to the upper surface 112 of the shower module 100, 700, 800,
(iii) attempting to
connect the drain fixture 135 or the drain assembly 134 to a plumbing line,
(iv) attempting to
lower a male drain top into the female drain top of the drain assembly 134,
(v) attempting to
insert the drain fixture 135 into the drain aperture 130, (vi) attempting to
have the lower surface
114 of the shower module floor 110 sit level on the subfloor once the drain
wall 132 or drain
fixture 135 is inserted into the opening in the subfloor, and (vii)
maintaining a constant pitch and
proper drainage of the upper surface 112 of the shower module floor 110 to the
drain aperture
130. Thus, to insure even cooling, it is important that the overall thickness
of material be kept
within certain limits. For example, the vertical distances in each of the four
situations described
below should be four inches or less:
(i) From the bottom edge 122 of each support rib 120 on the lower surface
114 to
the upper surface 112 of the floor 110;
(ii) From the bottom edge 122 of each support rib 120 on the lower surface
114 to
the top edge 123 of each pitching rib 121 on the upper surface 112 of the
floor
110;
(iii) From the lower surface of the bottom panel 160 to the top edge 123 of
each
pitching rib 121 on the upper surface 112 of the floor 110; and
(iv) From the lower surface of the bottom panel 160 to the upper surface 112
of the
floor 110.
[0069] Additionally, the difference between any two vertical distances
described in each of
the four (4) following situations should -be three inches or less:
(i) The largest vertical distance from the bottom edge 122 of any portion
of any
support rib 120 on the lower surface 114 of the floor 110 to the upper surface
112 of the floor 110, and the shortest vertical distance from the bottom edge
122 of any portion of any support rib 120 on the lower surface 114 of the
floor
110 to the upper surface 112 of the floor 110;
(ii) The largest vertical distance from the bottom edge 122 of any portion
of any
support rib 120 on the lower surface 114 of the-floor to the top edge 123 of
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any pitching rib 121 on the upper surface 112 of the floor 110, and the
shortest
distance from the bottom edge 122 of any portion of any support rib 120 on
the lower surface 114 of the floor 110 to the top edge 123 of any pitching rib
121 on the upper surface 112 of the floor 110;
(iii) The largest vertical distance from the lower surface of bottom panel 160
to the
upper surface 112 of the floor 110, and the shortest vertical distance from
the
lower surface of the bottom panel 160 to the upper surface 112 of the floor
110; and
(iv) The largest vertical distance from the lower surface of bottom panel
160 to the
top edge 123 of any pitching rib 121 on the upper surface 112 of the floor
110,
and the shortest vertical distance from the lower surface of the bottom panel
160 to the top edge 123 of any pitching rib 121 on the upper surface 112 of
the
floor 110.
[0070] The thickness of any sidewall 101, 102, 103, 104 should be equal to
or greater than
3/8 inches to insure that the polymeric material properly flows throughout the
cavity of the tool.
Each sidewall 101, 102, 103, 104 may be connected to the floor 110 such that
the orientation of
the sidewall 101, 102, 103, 104 is within 10 of vertical to the common
horizontal plane defmed
by the termination of the support ribs 120.
[0071] Additionally, in a preferred embodiment, the orientation of the
support ribs 120
should not impede the direction of flow of the polymeric material during
injection molding. For
example, the support ribs 120 may run parallel to, perpendicular to, or at an
acute angle to, the
direction of flow of material. The important consideration is that the ribs
are constructed in such
a manner that the material flows relatively evenly through the tool, does not
back up during the
injection molding process, and does not create voids in the fmished product.
In alternative
embodiments, the support ribs 120 may be arranged in a variety of
configurations, such as a
sunburst pattern 124 (see FIG. 7), a diamond pattern 125 (see FIG. 8), and a
honeycomb pattern
(see FIG. 9).
[0072] In an alternative embodiment, as shown in FIGs. 11-13, at least one
peripheral edge of
the floor 110 is not connected to a sidewall. The absence of at least one wall
allows the shower
module 1100, 1200 to provide access to physically impaired persons and meets
requirements
established by the Americans with Disabilities Act (ADA), 42 U.S.C. 12101-
12213 (2000).
Any sidewall 104 or combination of sidewalls 101, 102, 103, 104 may be
partially or completely
omitted by placing at least one insert into the cavity of the tool prior to
injecting the polymeric
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material, at a location corresponding to a sidewall 104 of the ADA shower
module 1100, 1200.
The insert fills all or a portion of the entire void in the tool intended to
form the corresponding
sidewall 104, thereby preventing polymeric material from flowing into the void
and forming the
sidewall 104. In this manner, the manufacturer may create a variety of shower
modules 100,
1100, 1200 from the same tool, with the only difference being which portion of
an entire sidewall
101, 102, 103, 104 is not included (e.g., a sidewall 103 along a longer side
of the shower module
1100, a sidewall 104 along a shorter side of the shower module 1200, two
sidewalls 102, 104 on
opposite edges of the floor 110 to create a "pass-through" shower module (not
shown), or two
adjacent sidewalls 101, 102 to create a corner shower module (not shown)). The
floor 110 of the
ADA shower module 1100, 1200 at the entrance to the shower, after having tile
installed on the
Upper surface 112, is virtually flush with the floor of the bathroom in which
the shower
module110, 1200 is installed, or slightly raised. Further, the shower module
1100, 1200 is
pitched from the peripheral edges of the floor 110 to the drain aperture 130.
In this manner, a
wheelchair or other mobility-assisting apparatus (e.g., a walker, crutches, a
cane, etc.) may freely
enter and exit the shower enclosure.
100731 Because the ADA shower modules 1100 have all or a portion of at
least one sidewall
completely removed, the edges of the sidewalls 101, 103 adjacent to the
removed sidewall are
unsupported, which creates potential problems when transporting the shower
module 1100 prior
to installation. In addition, shower modules 1400, 1500 (See FIGs. 14-15) with
and integrated
curb 140 which is lower than one or more adjacent sidewalls 101, 102, 103, 104
likewise have
portions of sidewalls that are not fully supported by adjacent sidewalls.
These unsupported or not
fully supported sidewall edges may break if the shower module 1100, 1200,
1400, 1500 is
accidentally dropped or mishandled. To provide temporary support, removable
support bars 150,
152 are connected between the upper edge of each sidewall 101, 103 and the
peripheral edge of
the floor 110 along the side missing a sidewall (or between= the upper edge of
each sidewall and
the curb 140 for those modules 1400, 1500 having an integrated curb 140 with a
lower height
than an adjacent sidewall). These support bars 150, 152 may be diagonal beams,
or solid shapes
(e.g., triangular, rectangular, etc.) created during the molding process, or
added after the shower
module 1110 has been formed. In the event that the support bars 150, 152 are
created during the
molding process, they may include fatigue lines along the intersection created
between the
support bar 150, 152 and the sidewall 101, 103, and the intersection between
the support bar 150,
152 and the floor 110. Alternatively, the fatigue lines may be created by the
manufacturer by
scoring the support bars 150, 152 along the above described intersections.
Implementation of the
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fatigue lines allow an installer to easily and conveniently break the support
bars 150, 152 away
from the shower module 1100 after the shower module has been set in place in
the area intended
for a shower enclosure. Thus, the possibility that the edges of the sidewalls
101, 103 become
damaged prior to installation is greatly reduced. Alternatively, the installer
may simply cut the
support bars 150, 152 away from the shower module 1100 after installation.
[0074] In a similar manner as described above, the height of a sidewall 104
or combination of
sidewalls 101, 102, 103, 104 may be lowered to a height suitable for
installing a modular curb
300 adjacent to the shower module 100. At least one insert that runs the
entire the length of a
sidewall 101, 102, 103, 104, or any portion thereof, is placed inside the
cavity of the tool prior to
injecting the polymeric material, at a location corresponding to a sidewall
104 of the ADA
shower module 1100, 1200. The height of the insert corresponds to the
difference in height
between a full sidewall 101, 102, 103 and the lowered sidewall 104. The insert
partially fills the
void in the tool intended to form the corresponding sidewall 104, thereby
preventing polymeric
material from flowing into the void and forming a sidewall 104 having a
lowered height. Inserts
may be placed within the tool at locations corresponding to any sidewall or
combination of
sidewalls, thus allowing the manufacturer to create a variety of shower
modules with a single
tool.
[0075] In another alternative embodiment, as depicted in FIGs. 14-16, at
least one side wall
104 may include an integrated curb 140 that is molded into the shower module
1500 during
fabrication. Similar to the methods described above, the tool may contain
voids in the cavity and
core, proximate to the location of any sidewall, corresponding to the shape of
the integrated curb
140. The manufacturer merely has to place inserts into the tool at the
location of the unwanted
curb to prevent the integrated curb from forming.
[0076] The use of inserts within the tool allows the manufacturer the
flexibility of creating a
wide variety of shower modules from a single tool. Each tool is an expensive
investment.
Additional charges are incurred every time a tool is changed out on the
manufacturing line. The
time required to change the tool is basically wasted time as the line is
shutdown in anticipation of
the new tool. Placing inserts into the tool, which are comparatively much less
expensive than
designing and purchasing individual tools for each permutation of sidewall,
also allows for a
much shorter downtime during the changeover as less time is required to fit or
remove an insert
than to completely remove and replace the whole tool. Thus, any combination of
placement of
sidewalls, height of sidewalls, integrated curbs, length of the shower module,
and width of the
shower module, may be accomplished using a single tool.
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[0077] The shower module 100 may also be constructed to assist in
preventing the spread of
fire between floors of a multi-leveled building. In one embodiment, the drain
wall 132 and an
area on the lower surface 114 of the floor 110 within a given radius (e.g., 8
inches) of the drain
wall 132 is coated with a fire retardant material. Thus, in the event that a
fire were to ignite in a
building one level below the bathroom where the shower enclosure is installed,
the fire is
hampered from spreading through the opening in the floor containing the drain
pipe and
engulfmg the shower module 100. Alternatively, the shower module 100 may be
molded from a
fire-retardant polyurethane foam. In addition, the area around the drain wall
132 that sits in the
plumbing hole in the subfloor can be filled with a fire-retardant material
after installation of the
shower module 100.
[0078] Tile should be retained on the sidewalls 101, 102, 103, 104 and the
upper surface 112
of the floor 110 using a resin based epoxy. The epoxy may contain 100% resin
solids or resin
solids mixed with a solvent, provided the epoxy contains 60% or more resin
solids.
[0079] 2. Method of Manufacturing
[0080] FIG. 17 illustrates an exemplary logic flow diagram 1700 executed by
a manufacturer
to implement a method for creating improved prefabricated shower modules
suitable for use in
constructing a tiled shower as described above. The manufacturer provides
(1702) a tool for
creating the leak-proof shower module 100. The tool includes a cavity and a
core which defme a
shape corresponding to a shape of the leak-proof shower module 100. The shower
module 100
may contain any, all, or a combination of the features detailed, supra, in
Section 1. For example,
the manufacturer may provide indentations in the tool that result in the
formation of the support
ribs 120 or the pitching ribs. The manufacturer may also place one or more
inserts into a voided
area of the tool (i) that corresponds to a sidewall 101, 102, 103, 104 of the
shower module 100,
thereby preventing the polymeric material from filling the voided area during
injection molding,
or (ii) corresponds to a portion of the length or width of the shower module
thereby preventing
the polymeric material from filling the voided area during injection molding.
In addition, the
manufacturer may mold a horizontal fatigue line 108 into one or more sidewalls
101, 102, 103,
104 by creating a raised tab along the length a voided area that corresponds
to the sidewall 101,
102, 103, 104 at a height suitable for removing a portion of the sidewall 101,
102, 103, 104 and
attaching a modular curb 300.
[0081] Next, the manufacturer inserts (1704) one or more forms into the
tool between the
cavity and the core at the location established for the drain aperture 130 for
the purpose of
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forming the drain aperture 130 in the floor 110 and the drain wall 132 of the
shower module 100.
The drain aperture 130 may have a uniform diameter or the drain aperture 130
may have one or
more diameters along the bottom portion of the drain aperture 130 for
inserting all or a portion of
a drain fixture 135 for connecting to the plumbing line, and a wider diameter
at the top portion of
the drain aperture 130 for inserting all or a portion of a plumbing fixture to
accommodate a drain
fixture top having a wider or variable diameter. Thus, the form may have a
uniform diameter, or
may contain a first portion corresponding to a drain fixture shape suitable
for connecting to a
plumbing line and a second portion corresponding to a drain fixture shape
suitable for
accommodating a the drain top of drain fixture 135. Alternatively, two forms
may be used,
wherein one form corresponds to a shape suitable for connecting to a plumbing
line and the
second form corresponds to a shape suitable for connecting to a plumbing line.
A drain aperture
reinforcing structure 136 may also be placed in the drain wall 132 and the
floor 110 surrounding
the drain aperture 130 to strengthen the area around the drain aperture 130.
100821 Next, the manufacturer injects (1706) a polymeric material into the
tool to produce the
leak-proof shower module 100. The polymeric material should be injected into
the tool such that
the material flows in a direction unimpeded by any support rib 120. Thus, the
polymeric material
should flow in a direction parallel, perpendicular, or at an angle of 900 or
less to any support rib
120 of the plurality of support ribs 120 or to any pitching ribs 121 of the
plurality of pitching ribs
121.
[0083] The shower module 100 is cooled in the tool and as it cools, the
polyurethane hardens
and cures. Before it is completely cooled and cured, it may be removed (1708)
from the tool and
clamped (1710) to a rigid surface (e.g., a table, a workbench, etc.) while the
shower module
continues to cool (1712) and cure. Thus, the possibility of warping or bowing
of the lower
surface 114 or the upper surface 112 of the floor 110 of the shower module 100
is minimized.
Additionally, the shower module 100 may actually spend less overall time in
the tool before
being removed as the steps taken during post-molding decrease the effects of
any warping or
bowing, thus allowing the shower module 100 to be removed faster than what
would typically be
acceptable. Thus, the manufacturing cycle-time per unit is reduced, which may
reduce the total
cost of the product.
100841 After the shower module 100 has cooled to a solid condition (before
or after removing
the clamps) the manufacturer may coat (1714) the drain wall 132 and an area on
the bottom
surface 114 of the floor 110 surrounding the drain wall 132 with a fire-
retardant material.
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[0085] Additionally, the shower module 100 may be modified to allow a
modular curb 300 to
be attached to a sidewall 101, 102, 103, 104 of the shower module 100. The
modification may be
made by breaking (1716) the selected sidewall 101, 102, 103, 104 along a
horizontal fatigue line
at a height sufficient to allow attachment of a modular curb 300 thereto, and
removing the excess
portion. Alternatively, the sidewall 101, 102, 103, 104 may be cut to the
appropriate height.
Finally, the modular curb 300 is attached (1718) to the remaining portion of
the sidewall 101,
102, 103, 104 by either the manufacturer (e.g., prior to shipment) or the
installer (e.g., in the
field).
[0086] After fabrication of the shower module 100 having a drain aperture
130 made for a
drain fixture 135, the, drain fixture 135 is inserted into the drain aperture
130 and a water-tight
seal is formed at one or more of (i) the upper surface 112 of the floor 110 at
or around the drain
aperture 130, (ii) the drain aperture 130, and (iii) the lower surface 114 of
the floor110 at or
around the drain aperture 130.
[0087] In an alternative embodiment, as illustrated in FIG. 18 by the
exemplary logic flow
diagram 1800, a prefabricated drain assembly 134 may be embedded within the
floor 110 and
drain wall 132 of the shower module 100 during injection molding. Similar to
the above process,
the manufacturer begins by providing (1802) a tool for creating the shower
module 100. The tool
includes a cavity portion and a core portion which define a shape
corresponding to a shape of the
shower module 100. As above, the shower module 100 may contain any, all, or a
combination of
the features detailed, supra, in Section 1.
[0088] Next, the manufacturer attaches (1804) a drain reinforcing structure
136, which
contains an opening in the center, to a prefabricated drain assembly 134 in
such a manner that the
edges of the interior diameter of the drain reinforcing structure 136,
interfere with the outer
diameter of the prefabricated drain assembly 134. The drain assembly 134 with
the attached
drain reinforcing structure 136 is then inserted (1806) inside the tool at a
location corresponding
to the location of the drain aperture 134 such that the drain reinforcing
structure 136 lies in a
horizontal plane in an intermediary position between the cavity and the core
of the tool. Next,
the manufacturer injects (1808) a polymeric material into the tool, thereby
embedding the drain
reinforcement structure 136 in the shower module 100 and integrating the drain
assembly 134
within the floor 110 of the shower module 100. As above, the polymeric
material should be
injected into the tool such that the material flows in a direction unimpeded
by any support rib
120. The manufacturer removes (1810) the integrated shower module 100 from the
tool, clamps
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(1812) the shower module 100 to a table (or other rigid surface) to prevent
movement, and allows
the integrated shower module to cool (1814) while still clamped to the table.
[0089] 3. The Prefabricated Modular Curb
[0090] Generally, when constructing a tiled shower enclosure, installers
build a curb at the
intersection of the shower enclosure and the bathroom floor that serves as a
dam to prevent water
from escaping onto the floor. Typically, the curb was simply constructed by
vertically stacking
two or three wooden 2x4" boards, covering the boards with a leak-proof liner,
and applying tile =
on top of the liner. At least one prefabricated curb 200, as illustrated in
FIG. 19, has previously
been offered for use in construction of shower enclosures. The prior art curb
200 simply consists
of a U-shaped form having a top wall 206, a front wall 204, and a rear wall
208. The distance
between the front wall 204 and the rear wall 208 is approximately the width of
a standard 2x4
202. The prior art curb 200 is typically designed to receive structural
support from 2x4' s 202
stacked in the same manner as when a curb is constructed manually.
[0091] An embodiment of the present invention, as shown in FIGs. 20-23,
includes an
improved prefabricated modular curb 300 suitable for use in constructing a
tiled shower, in
conjunction with a prefabricated shower module 100, and method of
installation. The modular
curb 300 includes an exterior wall 320, a top wall 330, and a mounting wall
310 that engages a
sidewall 101, 102, 103, 104 of a shower module 100 when installed proximate to
the shower
module 100. The top wall 330 extends perpendicularly from the upper edge of
the exterior wall
320 to the upper edge of the mounting wall 310. Alternatively, the exterior
wall 320 may be
taller than the mounting wall 310 such that the top wall 330 is pitched to
slope downwards
toward the sidewall 101, 102, 103, 104 of the shower module 100 when the
modular curb 300 is
installed adjacent to the sidewall 300. The outer surface of the exterior wall
320 and the outer
surface of the top wall 330 are suitable for retaining tile, stone, and/or
marble using an epoxy
containing 100% resin solids or resin solids mixed with a solvent.
[0092] The modular curb 300 may also, but not necessarily, include a bottom
wall 340 that
extends from the bottom edge of the exterior wall 320 to the bottom edge of
the mounting wall
310, and opposite to the top wall 330. At least one reinforcing curb rib 350
is attached to at least
one of to the top wall 330, the inner surface of the mounting wall 310, the
inner surface of the
exterior wall 320, the bottom wall 340 (if present), or any combination
thereof. The reinforcing
curb rib 350 runs perpendicular to, parallel to or at an acute angle to the
mounting wall 310 or the
exterior wall 320.
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[0093] The combination of the modular curb 300 with the shower module 100
offers
significant improvements over the prior art by combining a leak-proof shower
module with an
attached leak-proof mounting wall, thereby maintaining the leak-proof quality
of the overall
shower base system. In addition, the modular curb 300 may be manufactured from
a single tool
using a combination of inserts. Each insert corresponds to the cross-sectional
shape of the
modular curb 300, but has varying lengths. By placing or removing one or more
inserts, the
length of the prefabricated modular curb 300 may be customized through the
manufacturing
process. Alternatively, the modular curb 300 may simply be cut to the desired
length after
fabrication.
[0094] In one embodiment, the top wall 330 may include a horizontal lip 360
on the upper
surface along the length of one or both ends. The horizontal lip 360 should be
at least 1 inch tall
and at least 3/8 inches wide so that a standard-sized wallboard may rest on
the lip 360.
Additionally, the curb 300 may include a reinforcing curb rib 350 at one or
both ends, connected
perpendicularly to the exterior wall 320 and to the mounting wall 310 and
effectively enclosing
the corresponding end.
[0095] In another embodiment, the top wall 330 extends beyond the outer
surface of the
mounting wall 310 to terminate in a ledge 370 having a width substantially
equal to the width of
the sidewall 101, 102, 103, 104 of the shower module 100 (see FIG. 22). Thus,
when the
modular curb 300 is installed adjacent to the shower module 100, the ledge 370
extends over the
top of the sidewall 101, 102, 103, 104 and the outer edge of the ledge 370 is
substantially flush
with the inner surface of the sidewall 101, 102, 103, 104.
[0096] In an alternative embodiment, as shown in FIG. 23, the modular curb
300 may also
include an attachment mechanism 316, 318 located along the outer surface of
the mounting wall
310 for engaging a corresponding attachment mechanism 106 in the sidewall 101,
102, 103, 104
of the shower module 100. The modular attachment mechanism 316, 318 may be a
tab, a notch,
a slot, a tongue, a groove, a ridge, a peg, an aperture, an interlocking clip,
or any combination
thereof.
[0097] In one embodiment, the modular curb 300 may be constructed using
similar
polyurethane reaction injection molding techniques as described above in
relation to the
prefabricated shower module 100. The process of molding the modular curb 300
faces some
similar issues as when molding the shower module 100. For instance, the
direction of flow of the
polymeric material should be unimpeded by the reinforcing curb ribs 350 during
injection
molding in order for the material to flow properly. Thus, the reinforcing curb
ribs 350 should run
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parallel to or at an angle of 900 or less to the direction of flow of
polymeric material.
Additionally, to provide the proper support, the modular curb 300 should be
molded from a
polyurethane foam (which may also be fire-retardant) having a density of 12
pounds per cubic
foot or greater.
[0098] In another alternative embodiment, as shown in FIGs. 24-24A, a
prefabricated
modular curb 400 includes an outer mounting wall 410, an inner mounting wall
480, an exterior
wall 420, and a top wall 430. The top wall 430 is attached substantially
perpendicular to the
upper edge of the exterior wall 420, to the upper edge of the inner mounting
wall, and to the
upper edge of the outer mounting wall 410. The inner mounting wall 480 is
located at an
intermediary point between the outer mounting wall 410 and the exterior wall
420. The distance
from the outer mounting wall 410 to the inner mounting wall 480 is slightly
greater than the
width of a sidewall 101, 102, 103, 104 of the shower module 100, such that
when the curb 100 is
mounted adjacent to the shower module 100, the sidewall 101, 102, 103, 104 is
retained between
the outer mounting wall 410 and the inner mounting wall 480. The exterior wall
420 may be the
same height or taller than the inner mounting wall 480 so that the top wall
430 is horizontal or
slightly pitched towards the shower module 100 upon installation. The outer
mounting wall 410
is shorter than the inner mounting wall 480 and should rest on the floor 110
of the shower
module 100 upon installation. Additionally, the modular curb 400 may include
reinforcing curb
ribs 450 attached to at least one of the top wall 430, the inner mounting wall
480, and the exterior
wall 420.
[0099] FIG. 25 illustrates an exemplary logic flow diagram 2500 executed by
a shower
enclosure installer to implement a method for constructing a tiled shower
enclosure within an
area bounded by a subfloor and stud framing using a prefabricated modular curb
300 and a
prefabricated shower module 100. The subfloor includes a plumbing connection
that leads to a
sewer line or septic tank. The installer begins by applying (2502) a quantity
of adhesive material
on the subfloor within the area bounded by the stud framing. Next, the
installer sets (2504) a
prefabricated leak-proof shower module 100 in place on the subfloor within the
area bounded by
the stud framing. The shower module 100 should be positioned on the subfloor
such that the
support ribs 120 are in supporting engagement with the subfloor, at least one
sidewall 101, 102,
103, 104 is substantially adjacent to the stud framing, and the drain assembly
134 is in fluid
communication with the subfloor plumbing connection.
[0100] The installer then installs (2506) a prefabricated modular curb 300
adjacent to at least
one sidewall that is not adjacent to the stud framing. Exemplary methods of
installing the
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prefabricated modular curb 300 are detailed in the logic flow diagrams of
FIGs. 26 and 27.
Following the steps for implementing the method detailed by logic flow diagram
2600, the
, installer applies (2602) a quantity of adhesive material to the outer
surface of the sidewall 101,
102, 103, 104 and sets (2604) the modular curb beside the sidewall 101, 102,
103, 104 such that
the mounting wall 310 of the modular curb 300 is proximate to the sidewall
101, 102, 103, 104
and the top wall 330 is positioned at the same level or above the top edge of
the sidewall 101,
102, 103, 104. Next, the installer seals (2606) any gap between the mounting
wall 310 and the
sidewall 101, 102, 103, 104 using an epoxy based adhesive to form a water-
tight, leak-proof seal.
Additionally, or alternatively, the installer may fasten (2608) the modular
curb to the subfloor,
the framing studs, or the sidewall 101, 102, 103, 104 using brackets 380 and
screws 382 or any
other traditional fasteners (e.g., screws, nails, rivets, etc.). In the
finished tiled shower enclosure,
the fasteners are completely hidden from view by the application of tile.
[0101] Alternatively, the installer may set (2702) the prefabricated
modular curb 300
adjacent to the sidewall 101, 102, 103, 104 such that an attachment mechanism
106 (e.g., a tab, a
notch, a slot, a tongue, a groove, a ridge, a peg, an aperture, an
interlocking clip, etc.) along an
outer surface of the sidewall 101, 102, 103, 104 engages with a corresponding
attachment
mechanism 316, 318 along the outer surface of the mounting wall 310 of the
modular curb 300.
The installer may also connect the modular curb 300 to the sidewall 101, 102,
103, 104 of the
shower module 100 by inserting one or more screws 382 through the ledge 370,
engaging the
sidewall 101, 102, 103, 104, as shown in FIG. 22.
[0102] Referring back to FIG. 25, after installing the modular curb 300,
the installer then
attaches (2508) wallboard to the framing such that a lower edge of the
wallboard rests above and
is flush with any sidewall 101, 102, 103, 104 adjacent to the stud framing.
Finally, the installer
installs (2510) tile on the wallboard, the module sidewalls 101, 102, 103,
104, the floor 110, and
the modular curb 300, thereby resulting in a tiled shower.
[0103] 4. The Shower Bench and Ledge
[0104] The final component of the leak-proof modular shower enclosure
system 'includes a
shower bench or ledge, as illustrated in FIGs. 28-30. The combination of the
bench and ledge
with the shower module 100 offers significant improvement over prior art by
attaching a leak-
proof shower bench or ledge to a leak-proof shower module, at an attachment
point that is also
leak-proof, thereby maintaining the leak-proof integrity of the shower base
system. In addition,
the shower bench and shower ledge may each be made in their own tool using a
combination of
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inserts, which permit the shower bench and the shower ledge to be made with a
variable height,
variable length, and variable depth so that the shower bench and the shower
ledge can be
customized either through the manufacturing process or after fabrication by
cutting the shower
bench and the shower ledge to the desired dimensions. The term "shower ledge"
includes any
structure, regardless of specific height, width, or length and having a
substantially horizontal
surface, for use in constructing a tiled shower enclosure. A "shower ledge"
may or may not be
intended to support the weight of a person or persons. Thus, the use of the
term "shower bench,"
as used in the context of the following discussion is interchangeable with the
term "shower
ledge." Typically, a "shower bench" is simply a shorter version of a "shower
ledge."
[0105] In one embodiment, the shower bench 500 is designed for installation
between the
shower module 100 and a stud-framed wall of the tiled shower enclosure. The
shower bench 500
may include a rectangular seating surface 510, as shown in FIG. 28, connected
to an upper edge
of a sidewall 520 along each peripheral edge. The length of the shower seat
500 is preferably
equal to either the width or the length of the corresponding shower module 100
with which the
shower bench 500 will be installed. The lower edge of each sidewall 520
terminates in a
common plane that either rests on the subfloor of the shower enclosure or
connects to a
corresponding peripheral edge of an optional bottom plate 540.
[0106] One sidewall 520 is divided into an upper portion 522 and a lower
portion 524,
wherein the lower portion is set back from the upper portion 522 along the
entire length of the
shower bench 500. The lower portion 524 is taller than the height of a
sidewall 101, 102, 103,
104 of the shower module 100, and is set back from the upper portion 522 a
distance slightly
greater than the thickness of the sidewall 101, 102, 103, 104 of the shower
module 100. In this
marmer, when the shower bench 500 is installed adjacent to the sidewall 101,
102, 103, 104 of
the shower module 100 such that the sidewall 101; 102, 103, 104 of the shower
module 100
resides within the setback area, thereby preventing the weight of the shower
bench 500 from
resting on the sidewall 101, 102, 103, 104 of the shower module 100.
Additionally, as shown in
FIG. 30, the outer surface of the upper portion 522 of the shower bench
sidewall 520 should be
flush with the inner surface of the sidewall 101 so that when tile 505 is
installed to form the final
shower enclosure, the transition between the shower module 100 and the shower
bench 500 is
unnoticeable.
[0107] In an alternative embodiment, as shown in FIG. 29, the shower bench
600 includes a
triangular seating surface 610 connected to an upper edge of a sidewall 620
along each peripheral
edge. The seating surface 610 may be any geometric shape suitable for forming
a shower
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enclosure. Similar to shower bench 500, one sidewall 620 is divided into an
upper portion 622
and a lower portion 624, wherein the lower portion is set back from the upper
portion 622 along
the entire length of the shower bench 600, allowing the shower bench 600 to be
installed adjacent
to a prefabricated shower module 100 without the weight of the shower bench
resting upon the
sidewall 101, 102, 103, 104 of the shower module 100.
[0108] In one embodiment of the present invention, the shower bench 500 may
include at
least one support rib 530 attached to at least one of the seating surface 510,
any side wall 520,
and the bottom wall, or any combination thereof, and extending downward to
terminate coplanar
with the lower edge of each sidewall. Each support or reinforcing rib runs
parallel to,
perpendicular to, or at an acute angle to, any side wal1.530
[0109] When installed, the seating surface 510 may be horizontal or pitched
downwards
toward the prefabricated shower module 100. Additionally, the seating surface
510 may include
a horizontal lip 550 at least 1 inch tall and at least 3/8 inches wide along
at least one peripheral
edge to allow for a standard-sized wallboard to rest on the lip 550.
[0110] The seating surface and at least the upper portion 522 of the
sidewall 520 adjacent to
the sidewall 101, 102, 103, 104 of the shower module 100 have surfaces
suitable for retaining
tile, stone, or marble using an epoxy containing 100% resin solids or resin
solids mixed with a
solvent.
[0111] In one embodiment, the shower bench 500 may be constructed using
similar
polyurethane reaction injection molding techniques as described above in
relation to the
prefabricated shower module 100 and the modular curb 300. As in the case of
the shower
module 100 and the modular curb 300, the direction of flow of polymeric
material should be
unimpeded by the support ribs 530 during injection molding in order for the
material to flow
properly. Thus, the support ribs 530 should run parallel to, perpendicular to,
or at an angle of 90
or less to the direction of flow of polymeric material. Additionally, to
provide the proper
support, the shower bench 500 should be molded from a polyurethane foam (which
may also be
fire-retardant) having a density of 12 pounds per cubic foot or greater:
[0112] FIG. 31 illustrates an exemplary logic flow diagram 3100 executed by
a shower
enclosure installer to implement a method for constructing a tiled shower
enclosure within an
area bounded by a subfloor and stud framing using a prefabricated shower bench
500, a
prefabricated shower module 100, and optionally, a prefabricated modular curb
300. FIG. 32
illustrates an exemplary finished shower enclosure created using embodiments
of the
prefabricated shower bench 500, the prefabricated shower module 100, and the
prefabricated
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modular curb 300 as disclosed by the present invention. The installer begins
by mounting (3102)
a prefabricated shower bench 500, adjacent to the stud framing such that a
bench sidewall 520
that has a lower portion 524 set back from an upper portion 522 is facing the
area where the
shower module 100 is to be installed. The shower bench may be fastened to the
stud framing
using traditional fastening techniques (e.g., braces, screws, nails,
adhesives, etc.). Thus, when
someone sits on the shower bench 500, the person's weight is supported by both
the bench
support ribs 540 and the stud framing and not distributed to the shower module
100.
[0113] Next, the installer applies (3104) a quantity of adhesive material
on the subfloor
within the area bounded by the stud framing and the shower bench 500, and sets
(3106) the
shower module 100 in place on the subfloor within the area bounded by the stud
framing and the
shower bench 500. The shower module 100 is positioned on the subfloor such
that at least one
module sidewall 101 is substantially adjacent to the stud framing, and a
second module sidewall
102 rests underneath the lower portion 524 of the bench sidewall 520. The
inner surface of the
second module sidewall 102 is flush with an outer surface of the upper portion
522 of the bench
sidewall 520, and the drain assembly is in fluid communication with the
subfloor plumbing
connection. The installer may also, optionally, attach a prefabricated modular
curb 300 to a third
sidewall 104 using techniques described, supra, in Section 3 or use a shower
module 1400, 1500
with an integrated curb 140.
[0114] Finally, the installer attaches (3108) wallboard to the framing such
that a lower edge
of the wallboard rests above and is flush with the first module sidewall 101,
and finishes the
shower enclosure by installing (3110) tile, stone and/or marble on the
wallboard, the module
sidewalls 101, 102, 103, 104, the floor 110, the optional modular curb 300,
and the prefabricated
shower bench 500.
[0115] All features of the shower bench 500 and corresponding methods of
installation
described herein may be equally applied to creating a shower ledge simply by
extending the
height of the sidewalls 520.
[0116] As described above, the present invention encompasses a modular
system for creating
a tiled shower enclosure including one or more component pieces (e.g., a
prefabricated shower
module with or without an integrated curb, a prefabricated modular curb, a
prefabricated shower
bench, and a prefabricated ledge), and methods of manufacturing and installing
the associated
component pieces. With this invention, manufacturers may improve cycle times
for creating
component parts while reducing yield losses, thereby resulting in lower costs
for higher quality
products. Additionally, the system offers tremendous flexibility in creating
numerous
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combinations of component pieces, thereby providing many more options for
creating modular
shower enclosures. The system may be installed in the field in a fraction of
the time required
using traditional prior art methods, which greatly assists installers and
contractors when building
multiple enclosures (e.g., newly constructed condominiums, apartment
buildings, hotels,
dormitories, prisons, pre-manufactured housing, etc.).
[0117]
In the foregoing specification, the present invention has been described with
reference
to specific embodiments. However, the scope of the claims should not be
limited by particular
embodiments set forth herein, but should be construed in a manner consistent
with the
specification as a whole.
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