Abstract:
A preformed structural support for ceramic tile for use in constructing a horizontal support surface, such as a seat or a foot rest in a shower or the like installation environment is provided. The preformed structural support includes a base of a corrosion-resistant material that can be trimmed to conform to the irregularities of the structural walls to which it is to be installed against. The base includes tile receiving sides that are textured and are ready for the application of tile using a suitable adhesive, such as a thinset compound. The preformed structural support is installed without the use of penetrating fasteners, thereby preserving the integrity of the waterproofing of the shower.

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to seats and shelves used in showers, baths and the like, and more particularly, relating to a preformed structural support for use in the construction of seats for new and existing ceramic tile surfaces where the preformed structural support is site customizable to conform to the irregularities of the shower or bath wall structure. 
     BACKGROUND 
     Seats and shelves are desired fixtures in showers, baths and the like for providing architectural decoration, a place for sitting, a foot rest or a horizontal surface to store bathing related articles. In constructing such fixtures, it is important to preserve the waterproofing of the bath or shower, provide an appealing finished product, and also ensure the fixture can support loading, such as, for example, when a person sits or uses the fixture as a foot rest. 
     One usual method of constructing these fixtures includes a site-built wood frame structure that is attached to the rough frame of a shower or tub wall and/or floor. The wood frame structure is then waterproofed with one of several methods and then reinforced with expanded metal, wire mesh or other means. A sub-base or mortar is applied to all of the exposed surface areas, and then tile is placed over the mortar by means of a suitable bonding agent, such as thinset. Although this provides an appealing finished look it is problematic and has many draw backs. First, the construction method is very labor intensive, time consuming and requires a degree of skill that most general construction labors do not have. Further, if the waterproofing is not done correctly or is compromised the construction is prone to failure due to water penetration. Water damage in this area can lead to extensive repair costs. Further yet, the wood frame is likely to shrink and the wood frame members are likely to shift overtime resulting in cracking of the tile and grout finish and damaging the waterproofing. 
     A second usual method of constructing these fixtures includes building a support structure of concrete blocks during either the rough-in of the bath or shower or after waterproofing the bath or shower construction. The concrete blocks are individually arranged to form a perimeter wall that is then filled with concrete or a mortar mix to form a top horizontal surface. The surface of the concrete blocks and top horizontal surface are prepared for the application of tile using the typical various methods. Although this method attempt to eliminate the shrinking and shifting of the wood members experienced by the first method, this method also has many drawbacks. In this regard, it is more labor intensive, results in a heavier construction, and requires additional skills even over the first method. 
     One attempt to provide a better construction method and device for constructing such fixtures in showers and baths is disclosed in U.S. Pat. No. 5,542,218 (“the &#39;218 patent”), issued to Rompel on Aug. 6, 1996. The &#39;218 patent describes a corrosion-resistant self-supported frame of a pre-form shape, to which a mortar substrate and ceramic tile is applied, in order to produce corner seats and trays. 
     While the pre-form of the &#39;218 patent provides a ready made support structure for use in constructing corner seats and trays in showers or baths it requires the use of penetrating fasteners, such as, a threaded fastener to attach the pre-form to the shower or bath wall framing members, which requires penetrating the waterproofing of the shower or bath. Any penetration of the waterproofing can lead to water damage resulting in costly repairs. Additionally, the pre-form may not be capable of conforming to irregularities of the shower or bath walls. It is very common for abutting vertical walls in a building structure, such as, a bath or shower to not be perfectly square or plumb. The addition of surface tile can further add or exaggerate the wall irregularities. The pre-form of the &#39;218 patent is constructed with the expectation of the walls being square and plumb. However, if this is not the case during installation, gaps can result between the pre-form and the walls or the pre-form can be damaged by over tightening of the penetrating fasteners in attempt to close the gaps, either of which is likely to result in failure. An additional possible drawback of the pre-form of the &#39;218 patent, is the pre-form is designed to be elevated above the floor of the bath or shower and installed in a cantilever fashion. In some installations, it is desirable to have the seat extend down to the floor of the bath or shower, and the pre-form of the &#39;218 is not capable of providing this. 
     An additional attempt to provide a better construction method and device for constructing such fixtures in showers and baths is provided by T. Clear Corp. in their PreFormed™ tile ready shower seat which is lightweight, does not require wood framing and its installation does not compromise the waterproofing of the shower or bath. However, T. Clear Corp. instructs the walls to which the seat is to be installed against must be square and plumb and you must not cut the seat or otherwise damage the exterior coating of the seat. These requirements makes utilization of the seat less practical as most walls are not square or plumb and the seat can not be cut to conform to the irregularities of the walls. Further, it is likely during the tiling process tools or tiles will be dropped, and in this event, if the tools or tile impact the seat this may damage the exterior coating requiring costly replacement of the seat. 
     The disclosed preformed structural support for use in the construction of seats for new and existing ceramic tile surfaces is directed to overcoming one or more of the problems set forth above and other problems present in the art. 
     SUMMARY OF THE INVENTION 
     In general, in one aspect, a preformed structural support for ceramic tile for use in constructing a horizontal support surface, such as a seat or a foot rest in a shower or the like installation environment having structural surfaces for attachment of the preformed structural support thereto is provided. The preformed structural support includes a base unit having a plurality of inward facing sides, and plurality of outward facing sides, wherein at least one of the plurality of inward facing sides includes a lip at least partially around and projecting from the periphery thereof. Each lip having an interface surface for abutment with at least one structural surface, and wherein each of the plurality of outward facing sides is adapted for the application of tile thereon. 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. 
     Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
         FIG. 1  is a front perspective view of the preformed structural support shown installed in a typical installation environment, such as a shower; 
         FIG. 2  is a rear perspective view of the preformed structural support constructed under the principals of the present invention; 
         FIG. 3  is a front perspective view of the preformed structural support constructed under the principals of the present invention; 
         FIG. 4   a  is a partial cross-sectional view taken along line  4   a - 4   a  in  FIG. 3  showing the preformed structure support is shown installed as “new construction”; 
         FIG. 4   b  is a variation of  FIG. 4   b , where the preformed structural support is shown installed as “old construction”; 
         FIG. 5  is a partial cross-sectional view of two outward facing sides with tile applied to the sides; 
         FIG. 6  is a cross-sectional view taken along line  6 - 6  in  FIG. 2  showing a hollow interior configuration of the preformed structural support with internal reinforcement; 
         FIG. 7   a  is a top plan view of the preformed structural support with an alternate configuration; 
         FIG. 7   b  is a top plan view of the preformed structural support with an alternate configuration; and 
         FIG. 7   c  is a top plan view of the preformed structural support with an alternate configuration. 
     
    
    
     Similar reference characters denote corresponding features consistently throughout the attached drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIG. 1  of the drawings, there is shown a perspective view of a preformed structural support  10  for use in the construction of seats for new and existing ceramic tile surfaces constructed in accordance with the principals of the present invention installed in a typical installation environment  100  such as a shower or bath. The preformed structural support  10  is positioned in a corner formed by two vertical walls  12  and  14  and a horizontal floor surface  16 , herein referred to as structural surfaces. 
     With reference now to  FIGS. 1-3 , the preformed structural support  10  includes a base unit  18  of a desired size and shape constructed of a non-corrosive, rigid material. It is contemplated the base unit  18  being constructed of a plastic through injection molding or otherwise. It is further contemplated, the base unit  18  being constructed of a high-density plastic. A suitable high-density plastic may be ABS. The plastic material also may include a reinforcement material. A suitable reinforcement material may be a fibrous material, such as, for example, glass or carbon fibers. 
     The base unit  18 , with reference to the installation positioning, includes a plurality of inward facing sides  20 - 24  and a plurality of outward facing sides  26  and  28 . The base unit  18  is generally constructed to have a polygonal horizontal cross-sectional shape with two opposed and attitudinally spaced horizontal surfaces and a number of vertical surfaces equal to the number of sides of the polygon extending between the two horizontal surfaces. The desired installation position of the base unit  18  with respect to the installation environment&#39;s structural surfaces determines the number of inward facing sides and the number of outward facing sides. In one aspect, the base unit  18  includes at least one inward facing side and at least one outward facing side. In another aspect, the base unit  18  includes at least two inward facing sides and at least two outward facing sides. As illustrated, the base unit  18  includes two vertical inward facing sides  20 ,  22  and a horizontal side inward facing side  24 , and a vertical outward facing side  26  and a horizontal outward facing side  28 . The inward facing sides  20 - 24  may be continuous surfaces. The outward facing sides  26 ,  28  may be continuous surfaces. 
     A lip  30  extends at least partially around the periphery  32  of each inward facing side  20 - 24 . The lip  30  may extend from at least two peripheral edges of each inward facing side  20 - 24 . The lip  30  may extend from at least three contiguous peripheral edges of each inward facing side  20 - 24 . Each lip  30  includes an interface surface  34  for abutting with a structural surface of the installation environment  100 , which will be further explain in more detail below. The lip  30  may extend from the periphery  32  of its respective inward facing side  20 - 24  such that the interface surface  34  is at a spaced distance from the inward facing side. The  30  may extending from the periphery  32  of its respective inward facing side  20 - 24  such that the interface surface  34  is at a spaced distance from and generally parallel to the inward facing side. In one aspect, the lip  30  extends about 0.5 inches from the periphery  30  of its respective inward facing side  20 - 24 . In another aspect, the lip  30  extends less than about 0.5 inches from the periphery  30  of its respective inward facing side  20 - 24 . In another aspect, the lip  30  extends about 0.5 inches from the periphery  30  of its respective inward facing side  20 - 24  and if of a thickness of about 0.5 inches. In another aspect, the lip  30  extends less than about 0.5 inches from the periphery  30  of its respective inward facing side  20 - 24  and is of a thickness of about or less than 0.5 inches. 
     The lips  30  can be trimmed to conform to the irregularities and/or angles of the structural surfaces in relation to the adjacent structural surfaces to which the base unit  18  is to be installed against. For example, very often, the corner formed by two vertical walls abutting one another is rarely perfectly square forming, thus forming a ninety degree angle. Additionally, the floor surface of the installation environment is typically formed to have a slight slant towards a drain formed through the floor. In either of these events, it is impractical to first measure these angles and then request a manufacture to construct and ship a pre-formed seat structure having interface surfaces formed to match the measured angles. As such, being able to trim the lips  30  permits on-site customization of the base unit  18  to fit the intersections of the abutting structural surfaces, the irregularities of the structural surfaces and the angles of the structural surfaces. 
     The preformed structural support  10  can be installed as “new construction” meaning before the application of tile to the structural surfaces to which the base  18  is to be installed, as shown in  FIG. 4   a , or “old construction” meaning after application of tile to the structural surfaces as shown in  FIG. 4   b.    
     With particular reference to  FIG. 4   a , there is shown a partial, elevation sectional view of the preformed structural support  10  as shown in  FIG. 1 . While the below discussion is made in reference to only one vertical inward facing side, the same applies to the remaining vertical inward facing sides. The base  18  is installed with the vertical inward facing side  22  against a structural vertical wall or structural surface  12  and the horizontal inward facing surface  24  against the floor or structural surface  16  of the installation environment  100 . The base  18  is showing being installed as “new” construction meaning before the application of tiles to the structural surfaces. The vertical wall  12  includes a waterproofed outer surface  102  supported by wall framing  104 . The floor  16  is waterproofed and is a sub-base of the shower or bath. The interface surfaces  34  of the lips  30  of the inward facing sides  22  and  24  are shown trimmed and in contact with the surface  102  and floor  16  respectively. Note, the lip  30  of the inward facing side  24  has been trimmed to conform to the slight slope of the floor  16  ensuring a continuous contact between the interface surface  34  and the floor. A suitable adhesive  36  (partially cutaway to illustrate lips) is applied between the structural surfaces  102  and  16 , the inward facing sides  22  and  24 , and the interface surfaces  34  to secure the base  18  to the structural surfaces. A suitable adhesive may be a mortar mix or the like. Another suitable adhesive may be a single or multipart epoxy compound. The use of an adhesive as opposed to mechanical fasteners insures the integrity of the waterproofing of the structural surfaces. 
     With reference to  FIG. 4   b , the base  18  is showing being installed as “old” construction meaning after the application of tiles to the structural surfaces. Like above, vertical wall  12  includes a waterproofed outer surface  102  supported by wall framing  104  and additionally includes a layer of tiles  104 . The floor  16  is waterproofed and is a sub-base of the shower or bath. While not shown, the floor  16  could also have a layer of tiles. The interface surfaces  34  of the lips  30  of the inward facing sides  22  and  24  are shown trimmed and in contact with the layer of tiles  104  and floor  16  respectively. Note, the lip  30  of the inward facing side  24  has been trimmed to conform to the slight slope of the floor  16  ensuring a continuous contact between the interface surface  34  and the floor. A suitable adhesive  36  (partially cutaway to illustrate lips) is applied between the structural tile layer  104  and  16 , the inward facing sides  22  and  24 , and the interface surfaces  34  to secure the base  18  to the structural surfaces. A suitable adhesive may be a mortar mix or the like. Another suitable adhesive may be a single or multipart epoxy compound. The use of an adhesive as opposed to mechanical fasteners eliminates the need to penetrate the structural surfaces and insures the integrity of the waterproofing of the structural surfaces and prevents the requirement of drilling through the tile layer  104 . 
     With reference to  FIG. 5 , there is shown a partial cross-sectional view of base unit  18  with a plurality of tiles  38  applied to the outward facing surface  26 ,  28 . The outward facing sides  26 ,  28  may be textured or otherwise treated to permit the direct application of tile  38  with a suitable adhesive  40  to the outward facing sides. A suitable adhesive  40  for attaching tile  38  to the outward facing sides  26 ,  28  may be a thinset compound. In one aspect, the outward facing sides  26 ,  28  may have a plurality of recessed pockets  42 . The pockets  42  capture and retain the adhesive  40  for application of the tile  38 . The pockets  42  can be arranged in desired patterns on the outward facing sides  26 ,  28 . 
     Turning now  FIG. 6 , which is a horizontal cross sectional view of the base unit  18 , to reduce weight and manufacturing costs, the base unit may be constructed to have a hollow interior  44  that is defined by the sides  20 - 28 . An internal reinforcement  46  may be provided to support the sides of the base. In one aspect, the internal reinforcement  46  is provided in the form webbing that extends across the vertical sides  20 ,  22 ,  26  between the horizontal sides  24 ,  28 . The webbing  46  may be formed into any desired pattern that affords the most structural support while reducing weight and manufacture costs. In one aspect, as shown, the webbing  46  is generally rectangular. In another aspect, the webbing  46  may be honeycomb shaped. 
     While the above description of the preformed structural support  10  was made in reference to a base unit  18  having a triangular horizontal cross-sectional shape, the base unit  18  is generally constructed to have a polygonal horizontal cross-sectional shape with two opposed and attitudinally spaced horizontal surfaces and a number of vertical surfaces equal to the number of sides of the polygon extending between the two horizontal surfaces. For example, with reference to  FIGS. 7   a ,  7   b  and  7   c , the base unit  18  is shown of various different shapes. In  FIG. 7   a , the base unit  18  has a polygonal shape generally of a quarter circle and includes two horizontal sides (one not shown) and three vertical sides. In  FIG. 7   b , the base unit  18  has a polygonal shape generally of a truncated square, and includes two horizontal sides and five vertical sides. Likewise, in  FIG. 7   c , the base unit  18  has a polygonal shape generally of a square, and includes two horizontal sides and four vertical sides. The shape of the base unit  18  of the preformed structural support  10  should not be limited to the examples discussed herein, as the base unit may be constructed to have numerous shapes. 
     In use, the preformed structural support  10  is first dry fit to the structural walls to which it is to be attached, including any vertical walls and floor. The lip  30  of each inward facing side is trimmed by a plane, saw, knife or otherwise so as to shape the interface surface  34  thereof to conform to the irregularities and angles of the respective wall/floor. The lips  30  are trimmed also to ensure each interface surface  34  makes even contact with the surrounds walls/floor so the base unit  18  does not rock. Once the preformed structural support  10  is dry fit, a suitable adhesive is applied to the inward facing sides and interface surfaces and the base unit  18  is set into place. Once the adhesive is cured, tile is applied to the outward facing surfaces using known methods. 
     A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.