Manufactured Shower Pan
A manufactured shower pan includes a drain, a molded waterproof liner having a properly sloped floor and extending side walls, a honeycomb liner support, a solid curb system and a processed dry mud pack to provide aeration and drainage connected to the weep system in the drain.
This application claims priority from copending U.S. provisional patent application 60/928,007 filed May 7, 2007.
FIELD OF THE INVENTIONSThe inventions described below relate to the field of construction and more specifically to the field manufactured shower pans.
BACKGROUND OF THE INVENTIONSHistorically shower pan installation required several days to accomplish and depended on the skill of the craftsmen to not leak. The decrease in skill in the construction trades and the pressure to cut costs are making manufactured showers and pans more attractive. However, conventional manufactured showers and shower pans are either too flexible for ceramic tiles to remain attached over time or do not provide sufficient drainage beneath the tile and mold and fungus flourish.
SUMMARYA manufactured shower pan includes a drain, a molded waterproof liner having a properly sloped floor and extending side walls, a honeycomb liner support, a curb system and a processed dry mud pack to provide aeration and drainage connected to the weep system in the drain.
A manufactured shower pan 10 as illustrated in
Curb 12 is illustrated in
Pan support 14 is illustrated in
Pan liner 15 is a waterproof element as shown in
Curb shape 12S may alternatively be formed into pan liner 15 creating curb space 15C. Curb space 15C may be filled during manufacturing or during field installation with any suitable material such as high density expanding foam, PVC foams or other suitable fillers.
Mud pack 20 is a dry, generally planar element sized and sloped to fit within liner floor 15F and provide a substrate for attachment of ceramic tiles. Mud pack 20 provides a path for water absorbed through tile grout and thin set used to attach ceramic tiles to pass into drain 16.
Referring now to
The drain connector 35D has been discussed as centered in pan liner 35. Any suitable orientation of the drain connection may be used as long as the pan liner is formed with the drain connection in the predetermined location.
Alternate shower pan 40 of
Installation of alternate shower pan 40 may be accomplished by locating pan 40 with drain connector 40D engaging drain 54. Pan 40 may be secured to floor 53 and pan liner sides 46, 47, 48 and 49 may be secured to walls such as wall 51. If curb space 42 is filled at the factory and mud pack 52 is installed at the factory, pan 40 will be ready to support installation of tile or stone or other surface covering.
While the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Other embodiments and configurations may be devised without departing from the spirit of the inventions and the scope of the appended claims.
Claims
1. A manufactured shower pan comprising:
- a curb forming one or more sides of a generally horizontal polygon, the polygon oriented to enclose a drain;
- a honeycomb liner support within the curb providing vertical support and drainage slope for a molded waterproof liner;
- a molded waterproof liner resting on the honeycomb liner support forming a waterproof floor and sides with suitable drainage slope and a connection to the drain, the connection including a weep system; and
- a processed dry mud pack engaging the molded waterproof liner to provide aeration and drainage connected to the weep system in the connection to the drain.
2. The manufactured shower pan of claim 1 wherein the curb forms two sides of a rectangular polygon enclosing a drain.
3. The manufactured shower pan of claim 1 wherein the curb is formed of high density foam injected into a curb space in the pan liner.
4. The manufactured shower pan of claim 1 wherein the honeycomb liner support is formed together with the pan liner as one piece.
5. A manufactured shower pan for engaging a drain through a floor, comprising:
- a rectangular curb secured to the floor enclosing a shower floor including the drain;
- a support frame within the rectangular curb, the support frame having a drain access port for exposing the drain;
- a pan liner forming a waterproof layer over the rectangular curb and the support frame, the pan liner having a drain connector for connecting to the drain; and
- a mud pack secured within the pan liner.
6. The manufactured shower pan of claim 5 wherein the support frame comprises:
- a honeycomb lattice support frame within the rectangular curb, the support frame having a drain access port for exposing the drain.
7. The manufactured shower pan of claim 5 wherein the support frame comprises:
- a circle pattern lattice support frame within the rectangular curb, the support frame having a drain access port for exposing the drain.
8. The manufactured shower pan of claim 5 wherein the support frame comprises:
- a rectangular lattice support frame within the rectangular curb, the support frame having a drain access port for exposing the drain.
9. A method of installing a manufactured shower pan in a shower site containing a drain comprising the steps:
- securing a curb on one or more sides of the shower site;
- securing a pan support within the shower site adjacent the curb; and
- locating a pan liner having a drain connector and a mud pack over the curb and the pan support with the drain connector engaging the drain.
10. The method of claim 9 wherein the step of locating a pan liner further comprises the steps:
- locating a pan liner having a drain connector over the curb and the pan support with the drain connector engaging the drain; and
- securing a mud pack within the pan liner.
Type: Application
Filed: May 7, 2008
Publication Date: Nov 13, 2008
Inventors: James S. Barro (San Juan Capistrano, CA), F. Leon Peters (San Juan Capistrano, CA)
Application Number: 12/116,814
International Classification: A47K 3/00 (20060101);