Abstract
A method of manufacturing a customized shower pan or floor includes the steps in which the desired shower stall area is measured to determine an outer periphery with regard to the existing drain in situ and then a shower pan mold is constructed with both an outer and a drain periphery. In a first embodiment, a resin/filler is poured partway in to the mold and then pre-cut tiles are placed in a desired manner on top of the resin while it cures. In a second embodiment, a single slab is poured with a resin/filler mixed with crushed or powdered stone, metal, or the like. The set shower pan is then placed and the drain periphery is grouted to the existing drain and plumbed.
Claims
1. A method for fabricating and installing a shower pan to an existing drain at a shower stall location comprising the steps of: measuring said shower stall location to determine shower stall edge dimensions; locating an existing drain in relation to said shower stall edge dimensions to determine a drain periphery; forming a shower pan mold in accordance with said shower stall edge dimensions and said drain periphery; providing and then placing a plurality of tiles within said shower pan mold to form a shower pan surface; providing and then pouring a resin/filler into said shower pan mold over said plurality of tiles; curing said resin/filler; removing said cured resin/filler and said plurality of tiles from said shower pan mold such that said shower pan surface is uppermost; placing said shower pan surface with said cured resin/filler, into said shower stall location such that said drain periphery is aligned with said existing drain; fixing said drain periphery to said existing drain; and, plumbing said existing drain to said shower pan surface.
2. The method for fabricating and installing a shower pan according to claim 1, wherein said plurality of tiles provided and placed within said shower pan mold are pre-cut to fit said shower pan mold.
3. The method for fabricating and installing a shower pan according to claim 1, wherein said shower pan mold is made of a non-porous material.
4. The method for fabricating and installing a shower pan according to claim 1, wherein said shower pan mold is made of a polyurethane plastic.
5. The method for fabricating and installing a shower pan according to claim 1, wherein said shower pan mold is made of a metal.
6. The method for fabricating and installing a shower pan according to claim 1, wherein said shower pan mold is at least partially made of cut stone.
Description
BRIEF DESCRIPTION OF THE DRAWING FIGURES
(1) In the drawing figures, wherein similar features are denoted with similar reference numerals throughout the several views:
(2) FIG. 1 is a perspective overview of the shower pan of the present invention in place;
(3) FIG. 2 is a perspective view of a resin and filler pouring step in the manufacture of the present invention;
(4) FIG. 3 is a block diagram/flowchart showing the steps in performing the present invention;
(5) FIG. 4 is a perspective view of the curing step of the present invention with the shower pan in the mold before it is flipped over for placement;
(6) FIG. 5 is a perspective view of the present invention turned over, removed from the mold edges, and with the curb and step ready for installation;
(7) FIG. 6 is a perspective view of the present invention ready for installation in the desired location and with the curb and step incorporated; and,
(8) FIG. 7 is an overview of various tile designs that could be incorporated in the present invention.
DETAILED DESCRIPTION OF THE DRAWING FIGURES AND PREFERRED EMBODIMENTS
(9) An overview of the present invention is seen in FIG. 1. It is generally indicated at 10 and includes the shower pan 14, a shower pan facing (top) surface 18, a drain 22, and a pan mold edge 16. This prefabricated unit 10 is placed within a shower stall 12 and then simply plumbed in as will be discussed further below.
(10) Turning to FIG. 2, the initial concrete pouring step on-site is shown. The concrete 32 is poured into the base of the shower stall 12 as seen between the drain periphery 24 and the concrete pour edges 34. Also seen in FIG. 2 is the completed present invention 10 ready to be installed in place. In the factory (off-site or in a different location on-site) the mold for the shower pan 14 is prepared. Pan mold edges 16 are cut and fitted together to create a mold to receive the resin/filler matrix 20 as seen in FIG. 4. The pan mold edges 16 could be made from a variety of materials such as cut stone, various grades of plastics, metal such as stainless steel, or the like. Tiles 26 (as discussed below) are placed face down in the prepared mold to form the resulting shower pan face surface 18 and limestone powder is poured into the crevasses between the tiles 26. Then the resin 20 is poured. It is contemplated that the resin/filler 20 would be a material such as STYPOL which is a sprayable (or pourable) resin. STYPOL 040-4950-4953 is the fastest cure in colder temperatures with -4968 being the slowest cure for higher temps. (STYPOL is a registered trademark for synthetic resin compositions; the trademark being owned by CCP Composites, a Delaware partnership, P.O. Box 419389, Kansas City, Mo. 64141-6389.) The cure time needs to be kept in mind when the facing or tiling part of the manufacture process is reached, if a large number of individual tiles are going to be placed within/on the matrix. According to manufacturer's literature, STYPOL-6095, 6097, 6098 could be used for a marble matrix formation with 25% STYPOL and 75% calcium carbonate (with any necessary catalyst, depending on circumstances). This would provide a non-tiled shower pan surface. In any case, note that the resin/filler 20 is sprayed, poured, or otherwise placed within the pan mold edges 16 and the drain periphery 24. It should also be emphasized at this point that the sizes and shapes of the pan mold edges 16 are determined by the location into which the present invention 10 is to be installed. The sides of the shower stall are measured at the base and an entrance step, if desired, is accounted for. The location of the drain pipe that the shower will be plumbed to is noted and then the mold is constructed and the resin/filler is sprayed or poured within it as shown.
(11) FIG. 3 is a flowchart or block diagram of the steps of the present invention that shows both the on-site and off-site procedures.
(12) FIG. 4, as mentioned above, shows the curing step of the present invention. The times needed for curing can be predicted and/or influenced by composition of the resin/filler and temperatures. Tile designs can be pre-planned and pre-cut to make quick work of it while the resin/filler 20 is curing. This eliminates the need for an on-site tile layer when the shower pan is being installed. Additionally, this method eliminates the need for the tile layers to travel to various sites (or locations on-site) in that all the tile laying is done at a central location, either at the building site or at a shop.
(13) In FIG. 5, the curing step is over and the shower pan 14 has been turned over or flipped so that the shower pan face surface 18 is uppermost. The pan mold edges 16 have been removed and a curb and a step 30 are ready to be assembled and installed.
(14) In FIG. 6, the curb and step 30 is installed and the shower pan 14 is ready for placement in the predetermined location within a shower stall 12.
(15) Lastly, FIG. 7 shows several examples of the variety of tile patterns 26 that can be used with the present invention.
(16) While only several embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that many modifications may be made to the present invention without departing from the spirit and scope thereof.
