MXPA99000531A - Pre-fabricated shower module and method of shower construction - Google Patents

Abstract

A waterproof shower module comprising a pre-fabricated, integrally molded unit which forms a unitary base (10) having side walls (16) and a pitched floor (12) defining an opening (14) within which is incorporated a vertically adjustable drain. Each side wall includes an upper lip (18) forming a horizontal surface upon which wall board may be supported and flushly aligned with the side walls of the module such that a substantially continuous and uniform surface is formed which provides a suitable mounting surface for receiving shower tiles. The module floor includes a top surface and a bottom surface and defines a plurality of molded feet (12a) depending from the bottom surface, which feet function to support the module floor on the underlying subfloor. The module floor is uniformly pitched from each side wall to the drain opening. One of the side walls further defines a curb (20) and includes inner and outer curb surfaces and horizontal curb surface (24). Tile is installed on the module's surfaces and on the surrounding wall board. A method of installing a tiled shower using a pre-fabricated shower module.

Description

PRE-MANUFACTURED SHOWER MODULE AND METHOD FOR BUILDING THE SHOWER BACKGROUND OF THE INVENTION 1. Field of the invention The present invention relates to prefabricated shower modules, and in particular, to pre-molded water-proof shower modules, capable of being mounted in a level manner with surrounding pressed fiber boards and having surfaces to receive the tiles or stones installed on them. the same. 2. Description of the Background Technique The installation of showers in accordance with the common methods in the background technique is inefficient. Conventional shower facilities typically involve complicated constructions that use flexible shower sheet coatings. According to the conventional method, showers are formed: by adapting the shower with two-by-four-limb wood, whereby a frame and curb are formed; Ref.029321 cover the subsoil with felt or tarred paper; installing a coating comprising a flexible sheet of water-tight material on the floor of felt or tarred paper by bending and securing the sides of the material to two of the four members with suitable fasteners, creating a hole in the coating to provide drainage; install the stone wall dry; apply a layer of mortar (commonly referred to as "mud") to the side walls of the shower and the curb and allow the mud to harden; apply additional sludge to form a properly paved shower floor and allow the floor mud to harden, and after the shower construction has been formed and hardened, install matching shower tile adjacent to the adjacent press fiber boards to create a finished shower construction. Problems with the conventional method of shower manufacture include the formation of bulging corners caused by the bending of the coating, such bulging can cause irregularities in the side walls of the shower that are difficult to cover with tile in a non-uniform finish. In addition, conventional shower coatings are susceptible to sting by various objects and foot traffic until they are covered with tile. In addition, the installation of the tile is complicated by irregularities in the side walls and the slope of the floor for the shower. Still another problem with the conventional methods of making the shower are the difficulties experienced by the installer in the formation of substantially square corners. Still further, with the construction for conventional shower, the paving of the floor may not be satisfactory, whereby puddles of water are formed that are not properly drained. Accordingly, there is a need for a prefabricated shower module that allows efficient construction of a shower while avoiding the disadvantages present in the conventional methods of making showers.

BRIEF DESCRIPTION OF THE INVENTION A prefabricated shower module comprising an integrally molded, prefabricated unit, which forms a unitary base having side walls, and a paved floor defining an opening for drainage into which a vertically adjustable drain is incorporated. Each side wall includes an upper edge that forms a horizontal surface on which a suitable pressed fiber board can be supported and aligned in a level manner with the side walls of the module such that a substantially continuous and uniform surface is formed which provides a suitable mounting surface to receive the tiles for the shower. The module floor includes an upper surface and a lower surface and defines a plurality of molded legs that depend on the floor, such legs function to support the floor of the module on an underlying floor. The dependent legs lead to the formation of a plurality of depressions in the upper surface of the floor, such depressions facilitate the installation of the shower tile providing a suitable surface to receive and secure the tile mortar for the shower. The floor of the module is paved when necessary from each side wall to a drainage opening. One of the side walls further defines a curb and includes inner and outer curb surfaces and a horizontal curb surface. In the preferred embodiment, the horizontal curb surface is at a lower elevation than the remaining side walls of the module such that, in the case of a plugging in the drain, the rising water could flow on the curb instead of reach a level where water could potentially damage the pressed fiber board supported by the edges of the side wall. The surfaces of the module and the side walls are roughened so that they are well adapted to retain the tiles or the stones fixed thereto by means of a thin-film fixing adhesive. The shower module further includes a vertically integrally formed adjustable drain. The adjustable drain facilitates the installation of the variable thickness shower tile, to provide a drain that has a perforated drain plate that is flush with the surrounding tiles. The installation of the module for the shower involves first securing a section of drainage pipe, such as PVC, to the module adhesively using a suitable adhesive. The installer then places abundant amounts of sealant and adhesive material, known as "solid construction" material, on the subfloor where the module will settle. In addition, an abundant amount of solid construction material is placed over the subfloor around the drainage opening to seal the opening. The module is then placed in place making sure that the edges of the side wall are substantially adjacent to the two-by-four uprights which form the frame for the shower. The installer then seats the module in place, such as placing its weight on the module floor to ensure proper • and reliable seating. The pressed fiber board, such as a dry stone wall, can then be installed and secured to two-by-four mountaineers in such a way that the lower edges of the pressed fiber board are substantially adjacent to the wall lips. lateral and at the same level with the side walls of the module. Next, the wall covering, such as the tile, can be installed. Significantly, it is not required to add mud prior to the installation of the tile since the module is at the same level with the pressed fiber board. In addition, the tile is easily installed because the lower row of the tile sits perfectly along the top surface of the floor. In contrast, tile installation is complicated in conventional shower facilities that have mud-laid floors, since the floor surface placed with non-uniform mud requires the installer to make appropriate adjustments so that the bottom row of the tile is .le leveled. Then the additional tiles are installed on the floor of the module and on the surfaces of the vertical and horizontal curb. It has been found that the installation of the shower module of the present invention leads to substantial savings in both time and material. Specifically, the installation of a shower using the module of the present invention leads to the saving of substantial quantities of mud for the wall and mud for the floor, which could have been required if the conventional method had been used, as well as several hours of job. Finally, an installation using the module of the present invention ensures uniform installations having perfectly square corners. The shower module of the present invention is made from a waterproof material, durable, which provides a completely leak-proof shower module, which has adequate surfaces to receive the shower tile on it. Accordingly, it is an object of the present invention to provide a shower module which provides an efficient installation of a shower, covered with tile, finished. Still another object of the present invention is to provide a waterproof shower module which, when installed, provides side walls that terminate at an edge or peripheral support lip to support the pressed fiber board in a level manner with the walls side of the module. Still another object of the present invention is to provide a waterproof shower module having a floor which is supported by a plurality of integrally molded legs, whereby a rigid shower floor, capable of having shower tiles, is provided. mounted on it. Still another object of the present invention is to provide a waterproof shower module which includes a molded curb having a horizontal surface and a vertical surface, such surfaces each providing a mounting surface for the installation of the shower tile. . Still another object of the present invention is to provide a waterproof shower module having a vertically adjustable drain assembly to accommodate the shower tiles of various thicknesses. In accordance with these and other objects which will become apparent hereinafter, the present invention will now be described with particular reference to the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top plan view of a shower module of the present invention; Figure 2 is a front elevational view of the shower module shown in Figure 1; Figure 3 is a right side elevational view of the shower module; Figure 4 is a front top perspective view of the shower module; Figure 5 is a front top perspective view of an alternative embodiment of the present invention; Figure 6 is a front top perspective view of another alternative embodiment of the present invention; Figure 7 is a front top perspective view of yet another embodiment of the present invention; Figures 8a-c illustrate the shower module of the present invention during the installation thereof; Figure 9a is a sectional view of the shower module resting on a support sub-floor; Figure 9b is a sectional view of the shower module of Figure 9a, having a shower tile installed thereon. Figure 10 is a more detailed view of a portion of the shower module shown in Figure 9a. Figures 11 a-c illustrate alternative embodiments of the edge structure of the shower module.

DESCRIPTION OF THE PREFERRED MODALITIES Now with reference to the drawings, Figures 1-3 show a preferred embodiment of the shower module of the present invention, generally referred to as 10. The shower module 10 includes: a floor 12, which forms a plurality of molded legs 12a formed integrally, defining an opening for drainage 14; a peripheral side wall 16 defining an upper peripheral edge 18; a curb, generally referred to as 20, and including an inner vertical curb surface 22, a horizontal curb surface 24 and an external vertical curb surface 26. The floor 12, the side wall 16, and the curb 20 are attached to Form integral waterproof modules. The module 10 is made of a lightweight, durable, waterproof material and can be formed by a vacuum molding process in the desired shape. In the preferred embodiment, the shower module 10 is manufactured from Noryl EN-185 resin, such material is available from General Electric Corporarion. The floor 12 of the module is inclined from the surrounding side wall 16 towards the drainage opening 14. In the preferred embodiment, the floor 12 slopes approximately 1,905 cm (3/4") from the surrounding side wall 16 to the drainage opening 14, however, any suitable slope is considered within the scope of the invention The floor 12 further forms a plurality of molded legs 12a, downwardly dependent, integral.The molded legs 12a function as load bearing elements to support the floor 12 , in which they prevent bending In the preferred embodiment, the legs 12a are spaced 7.62 cm (three inches) from their center, however, any suitable spacing which prevents significant deflection of the module floor is considered within the range of The invention As best shown in Figure 3, the inclined floor 12 requires that the legs 12a vary in their total length such that each leg 12a will be in support contact with the subsoil of the underlying level. The side wall 16 is approximately 15.24 cm (6") in height, as measured from the intersection of the floor 12 and the side wall 16. Each side wall 16 terminates at a horizontal edge 18. In the preferred embodiment, the lip 18 forms a horizontal surface of at least 1.27 cm (1/2") and preferably is approximately 1,905 cm (3/4") As described more fully herein below, the lip or edge 18 functions as a wedge for the mounting of the fiberboard pressed to level with the side wall 16. The shower module 10 is further shaped such that one side thereof defines a curb 20 along at least a portion of the side length. Curb 20 includes at least one internal vertical curb surface 22, a horizontal curb surface 24, and an external vertical curb surface 26. In the preferred embodiment, the surface of the inner vertical curb 22 has a dimension of approximately 10.79 cm (4-1 / 4") in height when measured from the floor 12, the horizontal curb surface 24 has a dimension of approximately 11.75 cm (4-5 / 8"), and the external vertical curb surface 26 has a dimension of approximately 12.7 cm (5") such that the surface 26 terminates substantially adjacent to the underlying subfloor Curb 20 includes an amount of support material 27, such as expanded polystyrene, enclosed by surfaces 22, 24, and 26, as best shown in Figure 3. In the embodiment preferred, a vertically adjustable drainage assembly, including an external drainage element 30, is placed within the drainage opening 14 in a water-tight manner.The external drainage element 30 defines threads i Suitable external fittings for the threaded coupling with an externally threaded internal drainage element 32 having a perforated drain plate 34. The external drainage element 30 is suitable for connection to the drainage pipe components for draining the water from the shower. As is evident, the internal drainage element 32 is threadably coupled with the external drainage element 30 in such a way that the rotation of the internal element 32 causes the vertical adjustment of the internal element 32, and particularly of the plate 34, for the positioning of the internal element 32. the plate 34 level with the tile of the surrounding shower. Figure 5 shows an alternative embodiment of the shower module 10 of the present invention wherein the curb 20 extends partially along one side of the module. Figure 6 shows an alternative embodiment of the shower module of the present invention wherein the curb 20 is placed on a "short" side of the module 10. Figure 7 shows an alternative embodiment of the shower module of the present invention which is substantially square. Accordingly, any suitably sized shower module is considered within the scope of the present invention. In each modality, the module floor, the side walls, and the curb surfaces are capable of having ceramic or marble tiles installed directly thereto, using a thin-bed fixing mortar, a bonding material, suitable, or other suitable adhesive material. The installation of the shower module of the present invention is better illustrated in Figures 8 a-c and 9a and 9b. The shower module 10 of the present invention is installed in a shower area, which has been previously installed by suitable uprights 40 (hereinafter referred to as "uprights"), by first adhesively attaching a section of drain pipe 42, such as PVC , to the module, using a suitable adhesive. The drainage pipe will direct the water that is drained from the finished shower through appropriate drainage pipes into the structure, and finally to a sanitary sewer. The installer then places copious amounts of adhesive and sealant material, known as "solid construction" material 44 on the subfloor where the module will settle, and a generous amount of the solid construction material is placed around the drainage opening to seal the opening against the penetration of water. Next, the module 10 is placed or fixed in place making sure that the lip or edge 18 of the side wall is substantially adjacent to the uprights 40. The installer then securely places the module and assures proper seating thereof by placing the weight on the module floor. This can be done by the installer simply by walking on the 12th floor of the module 10. Next, the pressed fiber board 46, such as a suitable dry stone wall, is then installed and secured to the uprights 40 in such a way that the lower edges of the pressed fiber board are substantially adjacent to the edge or lip 18 of the side wall and flush with the surrounding side wall 16.

Next, the shower tile 48 can be installed on the pressed fiber board 46 and the surfaces of the modules. Significantly, sludge is not required prior to the installation of the tiles for the shower because the module is flush with the pressed fiber board. In addition, the tile 48 for the shower is easily installed in a level manner because the lower row of the tiles is easily fixed to the side walls 16 of the modules since the tiles rest in perfect horizontal alignment on the upper surface of the floor. In contrast, the installation of the tile for the shower is complicated in the facilities of conventional showers that have mud floors because the non-uniform mud floor surface requires the tile installer to make appropriate adjustments so that the lower row of the tile is level. The additional shower tile is then installed on the floor of the module 12 and on the surface 24 of the horizontal curb and the surfaces of the vertical curb 22 and 26. Figure 10 shows a partial view of the shower module of Figure 9a detailing the structures of the edge and the pressed fiber board. Figures 11 ac show alternative embodiments of the structure and the assembly of the edge 18. Specifically, Figure 1 a shows a horizontal edge 18 having a vertically extending portion 18 a, which is below the press fiber board 46 for preventing that the water goes under the structure of pressed fiber board / module. Figure 11b shows an alternative installation where a membrane 50 is placed on the pressed fiber board 46 and the side wall 16 to prevent water from running under the pressed fiber board / module structure. Figure 11c shows yet another alternative embodiment wherein a rigid L-shaped element 52 is sealingly connected to the lip or lip 18 to prevent water from running under the pressed fiber board / module structure. As is now evident, the shower module of the present invention provides an efficiently molded waterproof module, to facilitate the construction and installation of a shower. The use of the module in the construction of the shower, instead of conventional construction methods, leads to substantial savings in both material and work. In addition, a shower built using the shower module of the present invention is more suitable than a shower constructed using conventional methods and leads to a higher quality installation and a more uniform finish. The present invention has been shown and described here in what is considered to be the most practical and preferred embodiment. However, it is recognized that deviations from it can be made within the scope of the invention and that obvious modifications will occur to those skilled in the art.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Having described the invention as above, property is claimed as contained in the following

Claims (10)

1. A waterproof shower module for use in the construction of a shower covered with tile within a limited area or joined by a sub-floor and a frame or structure of uprights, the shower module is characterized in that it comprises: a molded unit integrally, prefabricated, forming a unitary module having a floor joined along a peripheral edge by a side wall and a curb, the side wall extends vertically from the peripheral edge of the floor and ends in a horizontal lip, the floor has a top surface inclined down from the peripheral edge to a drainage opening, the floor further defines a plurality of dependently dependent supporting legs, the dependent supporting legs descending end each one below the upper surface of the floor in a horizontal plane common; the curb formed along at least a portion of the peripheral edge of the floor, the curb defined by an internal surface extending upwards from the edge of the peripheral floor, a horizontal surface connected to the inner surface, and an external surface connected to the horizontal surface and extending downwards, the external surface ends in the horizontal plane.

2. A waterproof shower module according to claim 1, characterized in that the horizontal lip has a horizontal dimension of at least 1.27 cm (1/2").

3. A waterproof shower module according to claim 2, characterized in that the horizontal lip has a vertically extending portion.

4. A waterproof shower module according to claim 1, characterized in that it also includes a vertically adjustable drainage placed inside the drainage opening of the floor.

5. A module for a waterproof shower according to claim 1, characterized in that it also includes an amount of polystyrene within a gap defined by the internal vertical surface of the curb, the horizontal surface and the external vertical surface.

6. A waterproof shower module for use in the construction of a shower enclosed with tile within a limited area or joined by a subfloor and stud frame, the subfloor includes a plumbing connection that communicates with a sewer line , the shower module is characterized in that it comprises: an integrally molded unit, prefabricated, forming a unitary module having a floor joined along a peripheral edge by a side wall and a curb, the side wall extends vertically from the peripheral edge and ends in a horizontal lip; the floor has a top surface sloping downwardly from the peripheral edge to a drainage opening, the floor further defines a plurality of downwardly dependent supporting legs, the dependent supporting legs descending each end below the top surface of the floor , to support the floor on the subsoil; a vertically adjustable drain placed within the drainage opening; the curb formed along at least a portion of the peripheral edge of the floor, the curb defined by an internal surface extending upwards from the edge of the peripheral floor, a horizontal surface connected to the inner surface, and an external surface connected to the horizontal surface and extending downwards thereof, the external surface ends substantially adjacent to the subsoil; whereby the module is installed on the sub-floor in such a way that the legs are in support coupling with the sub-floor and at least a portion of the lip is substantially adjacent to the frame of uprights such that the pressed fiber board fixed to the frame is supported by the lip in a level manner with the side wall, and whereby the drain is connected so that the fluid flows to the plumbing connection of the subfloor, to drain the water from the shower to a sanitary sewer.

7. A waterproof shower module according to claim 6, characterized in that the downward slope from the peripheral edge to the drain opening comprises a change in vertical elevation of approximately 1,905 cm (3/4").

8. A waterproof shower module according to claim 6, characterized in that the horizontal lip has a horizontal dimension of at least 1.27 cm (1/2").

9. A waterproof shower module according to claim 6, characterized in that the floor, the side wall, and the curb, each define suitable surfaces to receive the shower tile installed on them.

10. A method of installing a shower covered with tile within a limited area or joined by a subfloor and a frame of uprights, the subfloor includes a plumbing connection communicating with a sewer line, the method is characterized in that it includes the steps of : apply a quantity of adhesive material on the subfloor within the area limited by the frame of uprights; fixing or placing a prefabricated shower module in place on the subfloor within the limited area or joined by the upright frame; the module comprises an integrally molded, prefabricated unit, which forms a unitary module having a floor joined along a peripheral edge by a side wall and a curb, the side wall extends vertically from the peripheral edge and ends in a lip horizontally, the floor has a top surface with a downward inclination from the peripheral edge to a drainage opening, the floor further defines a plurality of downwardly dependent supporting legs, the dependent back legs descending each end below the top surface of the floor to support the floor on the subsoil; a vertically adjustable drain placed inside the drain opening; the curb formed along at least a portion of the peripheral edge of the floor, the curb defined by an internal surface extending upwards from the edge of the peripheral floor, a horizontal surface connected to the inner surface, and an external surface connected to the horizontal surface and extending down therefrom, the external surface ends substantially adjacent to the ground; whereby the module is placed on the sub-floor in such a way that the legs are in supporting engagement with the sub-floor and at least a portion of the edge is substantially adjacent to the upright frame, and the drain is in fluid communication with the connection of underground plumbing; fixing the pressed fiber board to the frame such that at least a portion of the pressed fiber board is supported by the lip of the module and is flush with the side wall of the module; Install tile on the pressed fiber board and module surfaces, whereby it leads to a tile covered shower. SUMMARY OF I-A INVENTION The present invention relates to a waterproof shower module comprising an integrally molded, prefabricated unit, which forms a unitary base (10) having side walls (16) and a paved floor (12) defining an opening (14) inside which a vertically adjustable drain is incorporated. Each side wall includes an upper lip (18) which forms a horizontal surface on which the pressed fiber board can be supported and aligned in a level manner with the side walls of the module such that a substantially continuous and uniform surface is formed. which provides a suitable mounting surface for receiving tiles for the shower. The module floor includes an upper surface and a lower surface and defines a plurality of molded legs (12a) that depend on the lower surface, such legs function to support the floor of the module on the underlying subsoil. The module floor is paved evenly from each side of the wall to the drain opening. One of the side walls further defines a curb (20) and includes inner and outer curb surfaces and a horizontal curb surface (24). The tile is installed on the surfaces of the module and on the surrounding pressed fiber board. The invention also relates to a method of installing a shower covered with tile using a prefabricated shower module.