IPC분류정보
| 국가/구분 |
United States(US) Patent
등록
|
| 국제특허분류(IPC7판) |
|
| 출원번호 |
US-0725113
(2007-03-17)
|
| 등록번호 |
US-8209795
(2012-07-03)
|
|
발명자
/ 주소 |
|
| 출원인 / 주소 |
|
| 대리인 / 주소 |
|
| 인용정보 |
피인용 횟수 :
5 인용 특허 :
60 |
초록
▼
A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower includes a floor and a plurality of sidewalls wherein a first sidewall is taller than at least a portion of a second sidewall and the difference in height between the fir
A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower includes a floor and a plurality of sidewalls wherein a first sidewall is taller than at least a portion of a second sidewall and the difference in height between the first sidewall and the second sidewall is sufficient to permit the attachment of a modular curb to the second sidewall. The floor is bounded along peripheral edges by the plurality of sidewalls which extend substantially vertically from the edges. A method of installing a tiled shower is implemented in one embodiment by applying adhesive material on a subfloor within an area bounded by stud framing, setting the prefabricated shower module in place on the subfloor, installing a prefabricated modular curb proximate to at least one sidewall of the module, attaching wallboard to the framing, and installing tile over the wallboard, module and curb.
대표청구항
▼
1. A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower, the shower module comprising: a plurality of sidewalls including at least a first sidewall having a first height and at least a portion of a second sidewall having a
1. A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower, the shower module comprising: a plurality of sidewalls including at least a first sidewall having a first height and at least a portion of a second sidewall having a second height, the second height being less than the first height and wherein the difference between the first height and the second height is sufficient to permit the attachment of a modular curb to the second sidewall;the modular curb comprising: a mounting wall having an upper edge and a lower edge, an inner surface, and an outer surface, the outer surface adapted to positioned in proximity to a sidewall of a shower module;an exterior wall having an upper edge, a lower edge and an outer surface;a floor having an upper surface, a lower surface, and a plurality of peripheral edges, wherein the floor is bounded along at least two peripheral edges by the plurality of sidewalls, the plurality of sidewalls extending substantially vertically from the plurality of peripheral edges; andwherein the lower edge of the mounting wall and the lower edge of the exterior wall lie in substantially the same plane. 2. The shower module of claim 1, wherein at least the second sidewall includes a horizontal fatigue line located at a height which permits all or a portion of the second sidewall to be removed by breaking or cutting the portion from the second sidewall, thereby allowing installation of a modular curb adjacent to the second sidewall. 3. The shower module of claim 1, further comprising: a first attachment mechanism located along an outer surface at least one sidewall for engaging a corresponding second attachment mechanism of a modular curb. 4. The shower module of claim 3, wherein the first attachment mechanism is at least one of a tab, a notch, a slot, a tongue, a groove, a ridge, a peg, an aperture, an interlocking clip, and an adhesive material. 5. The shower module of claim 1, wherein any sidewall is connected to the floor in an orientation that is less than or equal to 10 degrees from a line which extends perpendicularly from the floor. 6. The shower module of claim 1, wherein a top surface of any sidewall is one of flat and pitched towards the shower module. 7. The shower module of claim 1, wherein any sidewall has a thickness equal to or greater than ⅜ inches. 8. The shower module of claim 1, wherein the shower module is formed by injecting polymeric material into one or more injection sites of a tool, the tool including a cavity and a core which define a shape corresponding to a shape of the leak-proof shower module; and whereby the polymeric material flows through the tool at one or more angles, each angle being 90 degrees or less to the flow direction of the polymeric material from the one or more injection sites. 9. The shower module of claim 1, wherein the shower module is molded from a polyurethane foam having a density equal to or greater than 12 pounds per cubic foot. 10. The shower module of claim 1, wherein the shower module is molded from a fire-retardant polyurethane foam. 11. The shower module of claim 1, wherein the floor and the at least one sidewall define surfaces suitable for retaining at least one of tile, stone, and marble installed thereon. 12. The shower module of claim 11, wherein the at least one of tile, stone, and marble are retained using an epoxy containing at least one of 100% resin solids and resin solids mixed with a solvent. 13. A method of installing a tiled shower within an area bounded by a subfloor and stud framing, the subfloor including a plumbing connection communicating with a sewer line, the method including the steps of: applying a quantity of adhesive material on the subfloor within the area bounded by the stud framing;setting a prefabricated leak-proof shower module in place on the subfloor within the area bounded by the stud framing, the module including: a plurality of sidewalls;a floor having an upper surface, a lower surface, and a plurality of peripheral edges, wherein the floor is bounded along at least one peripheral edge by at least one sidewall, the at least one sidewall extending substantially vertically from the at least one peripheral edge; andwhereby said module is positioned on the subfloor such that one of the lower surface and a plurality of ribs, is in supporting engagement with the subfloor, at least one first sidewall is substantially adjacent to the stud framing, and one of a drain assembly and a drain fixture attached to the module is in fluid communication with the plumbing connection;installing a prefabricated modular curb proximate to at least one second sidewall of the module, wherein the prefabricated modular curb comprises: a mounting wall having an upper edge, a lower edge and an outer surface, the outer surface adapted to positioned in proximity to a sidewall of a shower module; andan exterior wall having an upper edge, a lower edge, a first end, a second end an inner surface and an outer surface;wherein the lower edge of the mounting wall and the lower edge of the exterior wall lie in substantially the same plane;attaching wall board to the framing such that a lower edge of the wall board rests above and is flush with the at least one first sidewall; andinstalling tile on the wall board, the module sidewalls, the floor, and the modular curb, thereby resulting in a tiled shower. 14. The method of claim 13, wherein the step of mounting the prefabricated modular curb to the at least one second sidewall includes: applying a quantity of adhesive material to an outer surface of the second sidewall;setting the prefabricated modular curb adjacent to the second sidewall such that the mounting wall is proximate the second sidewall and the top wall is positioned at a height at least as tall as a height of the second sidewall; andapplying an epoxy based adhesive between the mounting wall and the second sidewall. 15. The method of claim 14, wherein the epoxy adhesive between the mounting wall and the second sidewall forms a water-tight and leak-proof seal between the mounting wall and the sidewall. 16. The method of claim 14, wherein the top wall terminates beyond the outer surface of the mounting wall in a ledge having a width substantially equal to a width of the sidewall of the shower module. 17. The method of claim 13, wherein the step of mounting the prefabricated modular curb to the at least one second sidewall includes: applying a quantity of adhesive material to an outer surface of the second sidewall; andsetting the prefabricated modular curb adjacent to the second sidewall such that the adhesive material affixes the mounting wall of the modular curb to the second sidewall in a position where an outer edge of the ledge is substantially flush with an inner surface of the second sidewall. 18. The method of claim 13, wherein the step of mounting the prefabricated modular curb to the at least one second sidewall includes: setting the prefabricated modular curb adjacent to the second sidewall such that a first attachment mechanism along an outer surface of the second sidewall engages with a corresponding second attachment mechanism along the outer surface of the modular curb. 19. The method of claim 13, wherein the step of mounting the prefabricated modular curb to the at least one second sidewall includes: setting the prefabricated modular curb adjacent to the second sidewall such that the mounting wall is proximate the second sidewall and the top wall is positioned at a height at least as tall as a height of the second sidewall; andfastening the modular curb to at least one of the subfloor, the framing stubs, and the second sidewall.
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