One piece shower pan and method of making same

摘要

A one piece shower drain pan, encapsulated in a water proof membrane, and the method of fabricating the one piece open drain shower pan, the method which includes providing extruded polystyrene (XPS) foam of the type which absorbs very little water; shaping the section of extruded polystyrene foam with a CNC router to obtain the desired slope in the floor; cutting a hole in the foam to produce the drain hole; cutting a curb from the XPS foam and gluing the foam to a pan base on the open sides. Splash walls are then cut from concrete wall board and glued to the sides having no curb, so that the glue serves as a bonding agent and provides a waterproof seal between the parts; after the glue has cured, spraying the entire pan assembly with a polyurethane or polyurea coating to completely encapsulate the entire pan with a waterproof membrane, which provides strength and rigidity and defines a one piece drain pan ready for installation.

主权项

1. A one-piece shower pan assembly, comprising:
a. a section of extruded foam having a generally flat bottom surface and an upper surface sloping to a central drain hole; b. a curb formed of the extruded foam; c. splash walls of concrete wall board of a ¼″ thickness glued to sides of the section of extruded foam; d. an outermost layer of polyurethane for encapsulating and strengthening the section of extruded foam, the curb formed of the extruded foam and the splash walls of concrete wall board glued to the sides of the section of extruded foam to define the one-piece shower pan assembly; and e. wherein a bottom portion of the one piece shower pan assembly consists of the generally flat bottom surface of the section of extruded foam encapsulated by the outermost layer of polyurethane.