Waterproof base with composite shower curb, and methods of fabrication and installation thereof

Abstract

A tile-ready shower base system including a composite curb, and methods of manufacturing and installing the same. A sloped structural core is provided having a top side and a bottom side. A first waterproof panel or coating is applied to the top side 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. The composite curb is provided along at least one side of the basin. Optionally, a compressible soft material or cushioned layer can be applied over the first waterproof panel of the sloped structural core.

What is claimed is: 
     
         1 . A waterproof shower base system 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;   an upright flange projecting above the top surface of the expanded polymer core about at least a portion of the periphery of the expanded polymer core; and   a curb along at least one side of the expanded polymer core, the curb comprising a base portion and a high-density anchoring cap portion, the base portion comprising a lightweight expanded foam body defining a height and a width, and the high-density anchoring cap portion comprising a fastener retaining material and having a width substantially matching the width of the base portion, the high-density anchoring cap portion being substantially permanently attached to the lightweight expanded foam body of the base portion.   
     
     
         2 . The waterproof shower base system of  claim 1 , wherein the upright flange has a thickness of no more than 0.25 inches. 
     
     
         3 . The waterproof shower base system of  claim 1 , wherein the waterproof top layer comprises a fiberglass mesh and epoxy resin. 
     
     
         4 . The waterproof shower base system of  claim 1 , further comprising an elastomeric waterproofing layer applied to at least a portion of its exposed exterior surfaces. 
     
     
         5 . The waterproof shower base system 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. 
     
     
         6 . The waterproof shower base system of  claim 1 , wherein the lightweight expanded foam body of the curb comprises a closed-cell foam. 
     
     
         7 . The waterproof shower base system of  claim 6 , wherein the closed-cell foam comprises expanded polystyrene. 
     
     
         8 . The waterproof shower base system of  claim 1 , wherein the high-density anchoring cap portion comprises a material selected from polyethylene, polyvinylchloride, polypropylene, acrylonitrile-butadiene-styrene, fiberboard, foamed PVC board, foam backer board and combinations thereof. 
     
     
         9 . The waterproof shower base system of  claim 1 , further comprising a sealant applied over external surfaces of at least the base portion. 
     
     
         10 . The waterproof shower base system of  claim 9 , wherein the sealant is compatible with a thinset adhesive grout. 
     
     
         11 . The waterproof shower base system of  claim 1 , further comprising at least one fastener for retention by the high-density anchoring cap portion. 
     
     
         12 . The waterproof shower base system of  claim 1 , further comprising a cushioning layer overlying the waterproof top layer. 
     
     
         13 . The waterproof shower base system of  claim 12 , wherein the cushioning layer comprises ethylene-vinyl acetate foam. 
     
     
         14 . The waterproof shower base system of  claim 12 , further comprising a slip resistant cap layer overlying the cushioning layer. 
     
     
         15 . A method of fabricating a shower base system, 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; and   installing a composite curb along at least one side of the expanded polymer core.   
     
     
         16 . The fabrication method of  claim 15 , further comprising attaching an upright flange projecting above the top surface of the expanded polymer core about at least a portion of the periphery of the expanded polymer core. 
     
     
         17 . The fabrication method of  claim 16 , wherein the upright flange has a thickness of no more than 0.25 inches. 
     
     
         18 . The fabrication method of  claim 15 , 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. 
     
     
         19 . The fabrication method of  claim 15 , further comprising applying a compressible soft material layer over the waterproof top layer secured to the top surface of the expanded polymer core. 
     
     
         20 . The fabrication method of  claim 15 , further comprising applying an elastomeric waterproofing layer to at least a portion of the shower base's exposed exterior surfaces. 
     
     
         21 . The fabrication method of  claim 15 , further comprising forming an annular surface of the drain receiving recess directed toward the top surface to define a drain clamping surface. 
     
     
         22 . The fabrication method of  claim 15 , wherein the composite curb comprises a base portion and a high-density anchoring cap portion, the base portion comprising a lightweight expanded foam body defining a height and a width, and the high-density anchoring cap portion comprising a fastener retaining material and having a width substantially matching the width of the base portion, the high-density anchoring cap portion being substantially permanently attached to the lightweight expanded foam body of the base portion. 
     
     
         23 . The fabrication method of  claim 15 , further comprising installing a sealing material across the interface between the expanded polymer core and the composite curb. 
     
     
         24 . The fabrication method of  claim 15 , further comprising installing tile over at least a portion of the composite curb. 
     
     
         25 . The fabrication method of  claim 15 , further comprising mounting a structural component to the composite curb by at least one fastener retained by the high-density anchoring cap portion. 
     
     
         26 . A method of installing a waterproof shower base, said method comprising:
 providing an assembly 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, said drain receiving recess defining an annular surface directed toward the top surface to define an upper drain clamping surface, the assembly further comprising a waterproof top layer applied over the top surface of the expanded polymer core, and a bottom skin applied to the bottom surface of the expanded polymer core at least around the drain opening;   placement of the assembly onto a substrate, with the drain opening aligned with a lower drain element in the substrate;   attaching an upper drain element against the drain clamping surface of the drain receiving recess of the assembly and in engagement with the lower drain element; and   installing a composite shower curb base along at least one side of the expanded polymer core.   
     
     
         27 . The installation method of  claim 26 , wherein the step of placement of the assembly onto a substrate further comprises applying a thin-set mortar between the substrate and the assembly. 
     
     
         28 . The installation method of  claim 26 , wherein the assembly further comprises a thin flange surrounding at least a portion of the expanded polymer core, and wherein a tile backer-board is installed overlying at least a portion of the thin flange. 
     
     
         29 . The installation method of  claim 26 , further comprising installing an adjustable drain top onto the upper drain element. 
     
     
         30 . The installation method of  claim 26 , further comprising leveling the assembly on the substrate. 
     
     
         31 . The installation method of  claim 26 , further comprising applying a silicone caulk between the lower drain element and the assembly. 
     
     
         32 . The installation method of  claim 26 , further comprising applying a thin-set mortar over the upper drain element within the drain receiving recess. 
     
     
         33 . The installation method of  claim 26 , further comprising applying tile over the waterproof top layer of the assembly. 
     
     
         34 . The installation method of  claim 26 , further comprising applying a compressible soft material layer over the waterproof top layer of the assembly. 
     
     
         35 . The installation method of  claim 26 , wherein the step of providing the assembly comprises determining at least one dimension of the substrate and having the assembly custom fabricated based on the determined at least one dimension of the substrate. 
     
     
         36 . A cushioned drainage floor assembly comprising:
 a sloped core, the sloped core comprising a top, a bottom, at least one sidewall, and a drain opening extending therethrough; and   a cushioning layer overlying the top of the sloped core.   
     
     
         37 . The cushioned drainage floor assembly of  claim 36 , wherein the cushioning layer comprises an opening substantially aligned with the drain hole of the sloped core. 
     
     
         38 . The cushioned drainage floor assembly of  claim 36 , further comprising a substantially vertically oriented flange secured to at least a portion of the perimeter of the sloped core to create a lip. 
     
     
         39 . The cushioned drainage floor assembly of  claim 36 , wherein the sloped core comprises a foam material. 
     
     
         40 . The cushioned drainage floor assembly of  claim 36 , comprising an expanded polystyrene core and an ethylene-vinyl acetate foam cushioning layer. 
     
     
         41 . The cushioned drainage floor assembly of  claim 40 , further comprising a slip resistant cap layer. 
     
     
         42 . The cushioned drainage floor assembly of  claim 40 , further comprising an epoxy mesh bottom skin. 
     
     
         43 . The cushioned drainage floor assembly of  claim 36 , further comprising a perimeter flange. 
     
     
         44 . A method of installing a drainage floor, said method comprising:
 preparing a subfloor surface;   applying a closed-cell foam core over the prepared subfloor surface; and   applying a compressible soft material layer over the closed-cell foam core.   
     
     
         45 . The method of  claim 44 , further comprising installing a drain through a drain opening through the compressible soft material layer and the closed-cell foam core. 
     
     
         46 . The method of  claim 44 , further comprising installing a perimeter flange around at least a portion of the closed-cell foam core. 
     
     
         47 . The method of  claim 44 , further comprising installing a curb around at least a portion of the closed-cell foam core.