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Shower pan

a shower pan and prefabricated technology, applied in the field of shower pans, can solve the problems of shower floor pan breakage, leakage out of the shower floor, light weight and thin units are therefore susceptible to damage,

Inactive Publication Date: 2007-11-22
SURFACING PROD INT
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The present invention provides a pre-formed shower floor pan that is pre-clad with various solid surface materials, such as tile, granite, marble, and fiberglass, at a production facility prior to shipment to the construction site. This eliminates the need for tile and plumbing work at the installation site. The shower floor pan can be easily installed in a shower stall and can replace a bath tub in hotels and other facilities being remodeled. The shower floor pan has reinforcing ribs and an integrally molded shower drain for strength and structure. The invention achieves low cost and provides a convenient and efficient solution for shower floor pan installation."

Problems solved by technology

These lightweight and thin units are therefore susceptible to damage during shipping.
Deformation of the shower floor pan, including the curb portion of the pan, that is caused by foot traffic if the supporting frame for the shower floor pan is not in tight contact with the shower floor pan, may result in breakage of the shower floor pan and resultant leaks out of the floor of the shower.
The construction of the framing for a shower stall is a time consuming task that requires skill and care, as well as a correspondingly large expense.
Errors in the framing may also not be detected until the shower stall is almost completed, at which time repairs are more costly and time consuming.
The preparation of the waterproof joint around the drain pipe is also a critical task that may require repair once the shower stall is finished and require excessive time and effort to repair.
The use of reinforcing ribs under the curb obviates the requirement to use additional framing under the curb portion of the shower pan, and decreases the time, effort and skill required to install the shower pan and thereby decrease the time and effort in constructing a shower stall.

Method used

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Examples

Experimental program
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first embodiment

[0047] As illustrated in FIG. 4, the upper surface of a solid piece of stone 65 that is, for example ⅞ inch to about 1 inch thick, is carved by a machine, such as a radial arm grinder / polisher, to form an upper 66 surface sloping to the drain 68 with a pitch of about ¼ inch per foot. The one piece grout free base is a solid panel of thin stone granite, adhered to the shower pan in one sheet. These shower bases may be available in at least four popular sizes: 36″×36″ (center drain); 34″×48″ (center drain); 34″×60″ (center drain); and 32″×60″ (left or right drain).

[0048] A sheet of interwoven bidirectional fiberglass backing about 1 mm thick is bonded to the lower surface of the stone base 65. The backing has high elasticity with high resistance to mechanical and chemical applications.

[0049] In the alternative, a backing formed by a 2 mm thick layer of reinforced aluminum bottom laminate, with a 1 mm reinforced plastic ply laminate between the lower surface of the stone and the alum...

second embodiment

[0063] As illustrated in FIGS. 5 and FIG. 6, the tiled unit utilizes a piece of stone 70 or 80 with a thickness of for example 8 mm. One inch equals 25.4 millimeters, abbreviated 25.4 mm per inch. This piece of stone has grooves 90 cut into it about 4 mm deep to look like separate tiles but remaining as one unitary piece. This piece of stone is flexed into the pitched pan (¼″ per ft.) and then the grout lines 90 are filled with a epoxy grout 95 such as LATICRETE® SpectraLOCK™ Grout, manufactured by LATICRETE International, Inc., 1 LATICRETE Park North, Bethany, Conn. 06524-3423 USA to provide additional strength. All substrates must have a minimum slope of at least ⅛ inch per 12 inches to promote positive drainage. However, many building codes call for a minimum slope of ¼ inch per 12 inches.

[0064]“Ultra Thin Stone Slabs and Tiles,”70 and 80, best illustrated in FIGS. 7 and 8, commercially available from Wanlong Stone Company, 4-S (A), Quingmeng Hi Tech Industrial Area, Quanzhou, F...

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PUM

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Abstract

A method of forming a pre-fabricated, integrally molded shower pan unit in which tile is installed at a manufacturing facility before shipment to the location where the shower is to be built. A backing sheet of fiberglass is bonded to the back of a sheet of granite or marble which is turned over and the face of the sheet of stone is scored or cut to form a panel with rows and columns of tiles secured together by the backing. A drain opening is formed in the panel, the panel is secured by adhesive to the floor of the shower pan, a drain pipe is installed and grooves in the panel are grouted.

Description

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a continuation-in-part of Provisional Application No. 60 / 793,390 filed Apr. 20, 2006, entitled SHOWER PAN, which is incorporated herein by reference in its entirety for all purposes. This application claims the benefit of U.S. Provisional Application No. U.S. 60 / 793,390 filed Apr. 20, 2006, the benefit of the filing date of which is hereby claimed under 35 U.S.C. Section 119(e).STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not applicable REFERENCE TO MICROFICHE APPENDIX [0003] Not applicable BACKGROUND OF THE INVENTION [0004] 1. Field of the Invention [0005] The present invention relates to prefabricated shower pans, and, particularly, to a pre-molded waterproof shower pan that is pre-clad with solid surface panels for replacement of a bath tub with a shower stall. [0006] 2. Description of the Background Art [0007] The construction of a shower stall requires that a waterproof structure be plac...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): A47K3/00
CPCA47K3/40
Inventor GANN, MARK
Owner SURFACING PROD INT