Waterproof base and methods of fabrication and installation thereof

• US 8,181,288 B1
• Filed: 06/04/2008
• Issued: 05/22/2012
• Est. Priority Date: 06/04/2007
• Status: Active Grant

• Current Assignee: Davis Intellectual Assets, LLC
• Original Assignee: KBRS Manufacturing, Inc.
• Inventors: Davis, Thomas A. Jr.
• Primary Examiner(s): Katcheves, Basil
• Assistant Examiner(s): Mintz, Rodney
• Application Number:
  US12/133,020
• Publication Number:
  US 20120124736A1
• Time in Patent Office: 1,448 Days
• Field of Search: 461/3, 467/9, 52/34, 52/35
• US Class Current: 4/613
• CPC Class Codes: A47K 3/40 Pans or trays
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A tile-ready shower basin, and methods of manufacturing and installing the same. A sloped structural core is provided having a topside and a bottom side. A first waterproof panel or coating is applied to the topside 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.

Claims

1. A waterproof base providing connection between a tile drain and a drainpipe, the waterproof base 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;

a rigid upright flange, the rigid upright flange projecting upwardly from the bottom skin and extending above the top surface of the expanded polymer core about at least a portion of the periphery of the expanded polymer core, the rigid upright flange directly abutting and surrounding at least a portion of the periphery of the expanded polymer core, and the rigid upright flange having a thickness of no more than 0.25 inches; and

an adjustable drain top having an upper drain flange for mounting over the drain receiving recess in the top surface of the expanded polymer core, and a drain conduit extending through the drain opening through the expanded polymer core for engagement with a drain clamp mounted to the drainpipe.

2. The waterproof base of claim 1, wherein the waterproof top layer comprises a fiberglass mesh and epoxy resin.

3. The waterproof base of claim 1, further comprising an elastomeric waterproofing layer applied to at least a portion of the base'"'"'s exposed exterior surfaces.

4. The waterproof base 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.

5. The waterproof base of claim 1, further comprising a curb along at least one side of the expanded polymer core.

6. A waterproof shower base 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 surrounding the drain opening, the drain receiving recess being configured to receive a standard tile drain;

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;

a rigid upright flange, the rigid upright flange projecting upwardly from the bottom skin and extending above the top surface of the expanded polymer core about at least a portion of the periphery of the expanded polymer core, the rigid upright flange directly abutting and surrounding at least a portion of the periphery of the expanded polymer core, and the rigid upright flange having a thickness of no more than 0.25 inches; and

a drain assembly comprising a drain clamp for attachment to an underlying drain body, and an adjustable drain top having an upper drain flange and a drain conduit, wherein the upper drain flange is installed over the drain receiving recess in the top surface of the expanded polymer core and grouted in place, and wherein the drain conduit extends through the drain opening of the expanded polymer core and into the drain clamp.

7. A method of fabricating a shower base, 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;

attaching a rigid upright flange, the rigid upright flange projecting upwardly from the bottom skin and extending above the top surface of the expanded polymer core about at least a portion of the periphery of the expanded polymer core, the rigid upright flange directly abutting and surrounding at least a portion of the periphery of the expanded polymer core, and the rigid upright flange having a thickness of no more than 0.25 inches;

installing a drain clamp to a drain body connected to a drain pipe;

installing an adjustable drain top having an upper drain flange and a drain conduit, wherein the upper drain flange is mounted over the drain receiving recess in the top surface of the expanded polymer core and the drain conduit extends through the drain opening through the expanded polymer core and through the drain clamp into fluid communication with the drain pipe;

adjusting the height of the upper drain flange of the adjustable drain top; and

applying a thin-set grout within the drain receiving recess in the top surface of the expanded polymer core and around the drain conduit of the adjustable drain top.

8. The fabrication method of claim 7, 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.

9. The fabrication method of claim 7, further comprising applying an elastomeric waterproofing layer to at least a portion of the shower base'"'"'s exposed exterior surfaces.

10. The fabrication method of claim 7, further comprising forming an annular surface of the drain receiving recess directed toward the top surface to define a drain clamping surface.

11. The fabrication method of claim 7, further comprising installing a curb along at least one side of the expanded polymer core.