Damage-resistant shower base and installation method

Abstract

A shower base includes a combination slab where a foam slab (tapered or flat or multi-tapered) having a sloped upper surface is covered with a thin deformation-resisting honeycomb slab (e.g., 0.25-0.30 inch thickness, or more or less). A waterproof membrane and tile are installed on the shower base at the installation site. The method of installation includes installing the premanufactured combination slab at an installation site, and applying a waterproof membrane and thinset-bonded tile with gap-filling grout. This provides a high quality, flexible design that is both efficient and cost-competitive after installation. The honeycomb is sufficiently thick to overcome compression and deformation issues prevalent during tile installation.

1 . A shower base apparatus for placement on a floor-defining structure with a drain opening, comprising:
 a foam slab with an upper surface and a floor-engaging lower surface; and   a honeycomb slab bonded to the upper surface of the foam slab to form a combination slab, the honeycomb slab forming a deformation-resisting layer on the foam slab, one of the foam slab and the honeycomb slab having a continuously sloped surface so that when bonded together and installed, any falling water will flow toward the drain opening.   
     
     
         2 . The shower base apparatus of  claim 1 , wherein the foam slab's upper surface is the continuously sloped surface. 
     
     
         3 . The shower base apparatus of  claim 2 , wherein the honeycomb slab has a continuous constant thickness and conforms when bonded to the upper surface of the foam slab to thus take on a shape of the upper surface of the foam slab. 
     
     
         4 . The shower base apparatus of  claim 1 , wherein the honeycomb slab is less than 0.500 inch. 
     
     
         5 . The shower base apparatus of  claim 4 , wherein the honeycomb slab is less than 0.300 inch. 
     
     
         6 . The shower base apparatus of  claim 5 , wherein the honeycomb slab is within +/−0.050 of a range of 0.10 inch to 0.30 inch. 
     
     
         7 . The shower base apparatus of  claim 1 , wherein the foam slab includes polystyrene material. 
     
     
         8 . The shower base apparatus of  claim 1 , wherein the foam slab is tapered and includes a sloped upper surface when supported horizontally. 
     
     
         9 . The shower base apparatus of  claim 8 , including a waterproof membrane on the honeycomb slab. 
     
     
         10 . The shower base apparatus of  claim 9 , including tile on the waterproof membrane. 
     
     
         11 . The shower base apparatus of  claim 1 , including a second combination slab identical in laminar construction to the first combination slab, but the first and second combination slabs being positioned with associated sloped upper surfaces sloping in different directions. 
     
     
         12 . The shower base apparatus of  claim 1 , including a second combination slab identical in laminar construction to the first combination slab, but the first and second combination slabs being positioned with associated sloped upper surfaces sloping in a same direction and defining a continuous combined slope. 
     
     
         13 . A water-directing apparatus for placement on a floor-defining structure with a drain opening, comprising:
 a foam slab with sloped upper surface and defining a drain-adjacent location; and   a honeycomb slab bonded to the foam slab and forming a deformation-resisting layer on the foam slab and taking on a slope of the sloped upper surface so that when installed, falling water will flow toward the drain-adjacent location.   
     
     
         14 . The apparatus of  claim 13 , wherein the sloped upper surface of the foam slab is shaped to cause falling water to flow toward a drain point. 
     
     
         15 . The apparatus of  claim 14 , wherein a combined thickness of the foam slab and the honeycomb slab defines two drain-adjacent edges and at least one drain-remote edge, the at least one drain-remote edge having a constant dimension and a maximum thickness of the apparatus, and all portions of the sloped upper surface including the two drain-adjacent edges sloping toward the single drain point. 
     
     
         16 . The apparatus of  claim 15 , wherein the at least one drain-remote edge includes two drain-remote edges. 
     
     
         17 . A water-directing apparatus for placement on a floor-defining structure with a drain opening, comprising:
 a support slab defining a planar geometric shape with linear edges and top and bottom surfaces, the top and bottom surfaces defining a maximum thickness dimension and a non-constant thickness dimension that combine to define a continuous slope extending toward a drain-adjacent location; and   a honeycomb slab bonded to the support slab and forming a deformation-resisting layer on the support slab and taking on a slope of the sloped upper surface so that when installed, falling water will flow toward the drain-adjacent location.   
     
     
         18 . A method of installing a shower base apparatus in a shower structure at an installation site, comprising:
 providing a slab assembly including a tapered or flat foam slab with sloped upper surface, and a honeycomb slab bonded to the sloped upper surface of the foam slab to form a deformation-resisting layer on the foam slab;   installing the slab assembly and a drain apparatus relative to a drain hole in the installation site;   bonding a waterproofing membrane to the slab assembly; and   installing tile on the waterproofing membrane.   
     
     
         19 . The method of  claim 18 , wherein the honeycomb slab is 0.10 to 0.30 inch thick. 
     
     
         20 . The method of  claim 19 , wherein the foam slab is 0.10 to 3.00 inch thick.