Patent Publication Number: US-11655626-B2

Title: Plastic components for installation in tiled wet environments

Description:
TECHNICAL FIELD 
     The disclosure relates to a plastic component for installation in tiled wet environments. 
     BACKGROUND 
     Changing consumer preferences, designer influences, and in some cases the unavailability of craftsmen skilled in conventional installation methods have driven changes in the way tiled showers and other tiled wet environments are constructed. In particular, the trend points toward simplified wet environment installation methods and systems. 
     To facilitate these trends, integrated systems have been developed that use lighter materials, and that can be installed using quicker, simplified methods. In some cases, these systems are formed over a substrate with a moisture barrier such as a waterproof liner, shower pan, or other water impermeable surface to prevent water from leaking from the wet area. Generally, one or more plastic components such as drain fixtures, shower curbs, and shower niches are set in mortar and bonded to the moisture barrier. Decorative tiles are then set in the mortar over the moisture barrier and over or around the plastic components to form the tiled wet area. However, these tiled wet environments are known to leak for a variety of reasons. 
     One reason for wet area leaks is that mortars do not bond well to plastics. For example, channels can form or be present at the boundary between the mortar material and the plastic component. Other leaks occur from insufficient bonding between the plastic material and the plastic component that destabilizes the plastic component within the tiles. Regardless of how the leaks are born, significant damage can occur to the structure of the edifice as a result of the water leaks. Such damage can be costly and time consuming to correct. 
     Some attempts have been made to include fabrics on the plastic component for improved bonding performance. However, such attempts have generated products that are still susceptible to water leaks because the fabrics eventually break down and delaminate, creating pathways for water to escape. In addition, if there is any movement over time in the edifice due to an earthquake, settling, or other event, the expanding or contracting of the edifice can create movement in the tiled wet environment, which, in turn, can lead to separation between the layers of the fabric, creating pathways for water to leak from the tiled wet environment. Other attempts have been made to apply a coating to the plastic component for improved bonding performance. These attempts, however, have also been unsuccessful because the coating eventually rubs off or separates from the plastic component, increasing the likelihood of leaks and costly damage. 
     Accordingly, there is a need for plastic components that incorporate certain design improvements over other plastic components for improved bonding with mortar materials in a tiled wet environment. 
     SUMMARY 
     Embodiments of the present disclosure advantageously provide plastic components with an integrated bonding interface for improved bonding with mortar materials in a tiled wet environment. Moreover, these plastic component embodiments can be configured as various components commonly used in tiled wet environments (e.g., showers and bathrooms), including, but not limited to, configurations of floor drains, shower niches, shower curbs, drain covers, linear floor drains, drain bodies, drain risers, or any other suitable component. 
     According to an embodiment, a plastic component for use in a tiled wet environment comprises a base structure comprising a first polymer material and an integrated bonding interface. The integrated bonding interface can include a second polymer material welded to or fused with the first polymer material at a boundary area between the base structure and the integrated bonding interface. More particularly, molecular bonds can be formed between the first polymer material and the second polymer material in the boundary area such that the integrated bonding interface is bonded and sealed to the base structure. 
     In an embodiment, the crystallinity of the second polymer material can be different than the crystallinity of the first polymer material. For instance, the second polymer material can be formed independently from the first polymer material such that the second polymer material has a different crystallinity than the first polymer material. The integrated bonding interface can thus be easily formed on the plastic component without modification and/or interference with the molding of the base structure or plastic component, beneficially simplifying production of the plastic component with the integrated bonding interface. 
     This molecular bonding between the first and second polymer materials beneficially prevents the integrated bonding interface from separating from the base structure, which, in turn, reduces the likelihood of the formation of pathways for water to pass or escape between the base structure and the integrated bonding interface. It also is less prone to separation and failure due to movement events such as earthquakes and settling. Further, the integrated bonding interface is fully submersible in water with less risk of degradation of the integrated bonding interface because the molecular bonding between the first and second polymer materials at or near the boundary area is resilient or substantially resilient to breakdown from water. This is beneficial because prior art drain components with surface coatings or fabric faces are known to breakdown over time and/or separate when repeatedly or constantly submersed in water. 
     Because the polymer materials of the base structure and the integrated bonding interface are fused together at the boundary area via the molecular bonding, the boundary area can also be waterproof, preventing or reducing the likelihood of water getting between the base structure and the integrated bonding interface. For example, the integrated bonding interface prevents water from weeping through the integrated bonding interface and/or through the boundary area between the base structure and the integrated bonding interface. 
     The integrated bonding interface also can include a plurality of aggregate particles dispersed and partially embedded in a mortar facing surface of the second polymer material of the integrated bonding interface to form a three-dimensional surface. The three-dimensional surface is adapted for capturing or locking mortar material in one or more spaces between the particles, which, in turn, helps physically bond the mortar material to the plastic component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects, and advantages of the present disclosure will become better understood regarding the following description, appended claims, and accompanying drawings. 
         FIG.  1    shows an upper perspective view of a plastic component including a bonding interface according to an embodiment. 
         FIG.  2    shows a bottom view of the plastic component of  FIG.  1   . 
         FIG.  3    shows a cutaway upper perspective view of a plastic component including a bonding interface according to another embodiment. 
         FIG.  4    shows a perspective view of a plastic component including a bonding interface according to another embodiment. 
         FIG.  5    shows a cross-section view of a plastic component including a bonding interface according to an embodiment. 
         FIG.  6    shows a cross-section view of a plastic component including a bonding interface according to another embodiment. 
         FIG.  7    shows a cross-section view of a plastic component including a bonding interface according to another embodiment. 
         FIG.  8    shows a cross-section view of a plastic component including a bonding interface according to another embodiment. 
         FIG.  9    shows a cross-section view of a plastic component including a bonding interface according to another embodiment. 
         FIGS.  10 - 15    illustrate production of a plastic component including a bonding interface according to an embodiment. 
     
    
    
     The drawing figures are not necessarily drawn to scale, but instead are drawn to provide a better understanding of the components, and are not intended to be limiting in scope, but to provide exemplary illustrations. The figures illustrate exemplary configurations of drain systems, and in no way limit the structures or configurations of a drain system and components according to the present disclosure. 
     DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS 
     A better understanding of different embodiments of the disclosure may be had from the following description read with the accompanying drawings in which like reference characters refer to like elements. 
     While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are in the drawings and are described below. It should be understood, however, there is no intention to limit the disclosure to the specific embodiments disclosed, but on the contrary, the intention covers all modifications, alternative constructions, combinations, and equivalents falling within the spirit and scope of the disclosure. 
     It will be understood that unless a term is expressly defined in this application to possess a described meaning, there is no intent to limit the meaning of such term, either expressly or indirectly, beyond its plain or ordinary meaning. 
     Embodiments of the present disclosure advantageously provide plastic components with an integrated bonding interface for improved bonding with mortar materials in a tiled wet environment. Moreover, these plastic component embodiments can be configured as various components commonly used in tiled wet environments (e.g., showers and bathrooms), including, but not limited to, configurations of floor drains, shower niches, shower curbs, drain covers, linear floor drains, drain bodies, drain risers, or any other suitable component. For example, embodiments of the plastic component can be configured as a drain body installable in a tiled floor, as shown in  FIGS.  1  and  2   . An exemplary drain body  12  includes a lower portion  14  defining an outlet and configured to mate with a plumbing system or a drain pipe, and an upper portion  16  having an elongate configuration defining an opening and a flange  18  extending around the opening. The flange  18  can be a bonding flange sized and configured to be pressed against thin set mortar on an underlying support structure and optionally to provide an adhering or bonding surface for bonding the drain body  12  to a moisture barrier and/or thinset mortar. 
     As shown in  FIGS.  1  and  2   , upper and lower surfaces of the upper portion  16  include an integrated bonding interface  20 . As described in more detail below, the integrated bonding interface  20  is configured for easy creation on different kinds of profiles on the drain body  12 , improving the overall production and bonding performance of the drain body  12 . For instance, the integrated bonding interface  20  can be formed on the top, underside, and/or side surfaces of the upper portion  16 . Optionally, the integrated bonding interface  20  can be formed on sidewalls within openings and cavities. 
     In the illustrated embodiment, the integrated bonding interface  20  on the underside of the flange  18  is configured to improve bonding between the underside of the flange  18  and a thinset mortar material, attaching and supporting the drain body  12  on a subfloor or substrate. The integrated bonding interface  20  on the upper surface of the drain body  12  is configured to improve bonding between the upper surface of the drain body  12  and thinset mortar in a surface waterproofing installation of a tile floor. For instance, the drain body  12  can be installed in a subfloor with one or more waterproof panels around the drain body  12 . A thinset mortar material can then be applied to at least a portion of the upper surface of the flange  18 , and a moisture barrier can be bonded to the flange  18  and at least part of the upper surface of the waterproof panels surrounding the drain body  12 . An upper drain component can then be installed in the drain body  12  and tiles can be installed around the upper drain component on the moisture barrier using thinset mortar material and grout material. 
     As noted above, the integrated bonding interface  20  of the drain body  12  provides a three-dimensional surface that is sealed and bonded to the drain body  12  so as to improve bonding with the mortar materials in the tiled wet floor and to reduce the likelihood of water leaks via the boundary between the integrated bonding interface  20  and the drain body  12 . It will be appreciated that the drain body  12  can be formed of any suitable plastic material such as Acrylonitrile butadiene styrene (ABS) or Poly Vinyl Chloride (PVC). While the drain body  12  is described with an upper rectangular portion with a circular lower portion, it will be appreciated that the drain body  12  can have any suitable shape and/or configuration. 
     Embodiments of the plastic component for installation in a tiled wet environment can also be implemented as a drain body having a circular configuration, as shown in  FIG.  3   . An exemplary drain body  22  can include a lower portion  24  defining an outlet and configured to mate with a plumbing system or a drainpipe, and an upper portion  26  having a circular configuration defining an inlet and a flange  28  surrounding the inlet. At least an upper surface of the flange  28  includes an integrated bonding interface  30  like in the previous embodiment. Optionally, the sides and underside of the flange  28  can also include the integrated bonding interface  30 . Moreover, because of the ease of creating the integrated bonding interface  30 , the integrated bonding interface  30  can be selectively or strategically located on different surfaces on the drain body  22 . For instance, a transition between the flange  28  and the opening can define a curvature. The integrated bonding interface  30  can be located along at least a portion of the curvature. 
     Like discussed above, the integrated bonding interface  30  provides a three-dimensional surface that is sealed and bonded to a base material of the drain body  22  so as to improve bonding with the mortar materials in a tiled wet floor and to reduce the likelihood of water leaks via the boundary between the integrated bonding interface  30  and the base material. It will be appreciated that the drain body  22  can be formed of any suitable plastic material such as ABS or PVC. 
     By way of another example, embodiments of the plastic component for installation in a tiled wet environment can be configured as a shower niche as seen in  FIG.  4   . An exemplary shower niche  32  can include a generally rectangular housing  34  having a pair of spaced apart sides  36 , a top  38  and a bottom  40 . The housing sides  36 , the top  38 , and the bottom  40  form a cavity  42  having an open front  44  dimensioned to receive bathing products. A mounting flange  46  extends outwardly from the open front of the housing cavity  42  around the entire periphery of the housing  34 . When the housing  34  is installed within a shower, this outwardly extending flange  46  can abut against the shower wall. The shower niche  32  is dimensioned to be recessed between two adjacent framing members so that at least a portion of the flange  46  abuts against the shower wall and can be tiled over. 
     The shower niche  32  can be made of ABS, PVC, or another plastic material and at least the flange  46  can include an integrated bonded interface  50  similar to the interfaces described above. The integrated bonded interface  50  provides a three-dimensional surface that is sealed and bonded to a base material of the shower niche  32  so as to improve bonding with the mortar materials in the tiled shower wall and to reduce the likelihood of water leaks via the boundary between the integrated bonding interface  50  and the base material. Optionally, the housing cavity  42  can include the integrated bonded interface  50  so that tiles can be set in thinset mortar securely bonded to the integrated bonding interface  50  of the housing cavity  42 . 
     Exemplary cross sections of plastic component embodiments will now be described in additional detail.  FIGS.  5  and  6    illustrate a cross section of a plastic component  100  according to an embodiment. It will be appreciated that the plastic component  100  can be any plastic component adapted for installation in a tiled wet environment. For instance, the plastic component  100  can be a square floor drain, a circular floor drain, a linear floor drain, a shower niche, a soap holder, a drain cover, a drain body, a drain riser, or any other suitable plastic component. 
     The plastic component  100  comprises a base structure  102  and an integrated bonding interface  104 . The base structure  102  can comprise a first polymer material  106  and the integrated bonding interface  104  comprising a second polymer material  108  fused with the first polymer material  106  of the base structure  102 . Preferably, the first polymer material  106  and the second polymer material  108  are the same. For instance, the first polymer material  106  and the second polymer material  108  can comprise ABS. In other embodiments, the first polymer material  106  and the second polymer material  108  can be different. 
     The second polymer material  108  can have a different crystallinity than the first polymer material  106 . Crystallinity as used herein refers to the degree as to which there are regions where the polymer chains are aligned with one another. In an embodiment, the second polymer material  108  can have a different crystallinity than the first polymer material  106  because the second polymer material  108  can be processed or formed differently than the first polymer material  106 . For instance, the base structure  102  can comprise a plastic molded part and the integrated bonding interface  104  can be formed independent of and/or subsequent to formation of the base structure  102 . The integrated bonding interface  104  thus beneficially does not interfere with, complicate, or slow down the process of forming the base structure  102 . 
     A plurality of aggregate particles  110  are dispersed and partially embedded in a mortar facing surface  112  of the second polymer material  108  of the integrated bonding interface  104  to form a three-dimensional surface for capturing or locking mortar material  60  in one or more spaces  114  defined between the aggregate particles  110 , which, in turn, helps physically bond the mortar material  108  to the plastic component  100 . The plurality of aggregate particles may be arranged such that individual particles thereof project from the mortar facing surface  112  of the second polymer material  108  of the integrated bonding interface  104 . For example, 25%, or at least 25%, of a surface area of the individual particles may extend outside of the second polymer material  108 , or 30%, at least 30%, 50%, or at least 50%. 
     The first polymer material  106  of the base structure  102  is welded to or fused with the second polymer material  108  of the integrated bonding interface  104  at a boundary area  116 . More particularly, molecular bonds are formed between the first polymer material  106  and the second polymer material  108  in the boundary area  116  such that the integrated bonding interface  104  is bonded and sealed to the base structure  102 . This molecular bonding between the first and second polymer materials  106 ,  108  beneficially prevents the integrated bonding interface  104  from separating from the base structure  102 , which, in turn, reduces the likelihood of the formation of pathways for water to pass or escape between the base structure  102  and the integrated bonding interface  104 . It also is less prone to separation and failure due to movement events than prior art drain systems. Further, the integrated bonding interface  104  is fully submersible in water with a reduced risk of degradation of the integrated bonding interface  104  because the molecular bonding between the first and second polymer materials  106 ,  108  at or near the boundary area is resilient or substantially resilient to breakdown from water. This is beneficial because prior art drain components with surface coatings or fabric faces are known to breakdown over time and/or separate when repeatedly or constantly submersed in water. 
     Because the base structure  102  and the integrated bonding interface  104  are also sealed together at the boundary area  116  via the molecular bonding, the boundary area  116  is also waterproof, preventing or reducing the likelihood of water getting between the base structure  102  and the integrated bonding interface  104 . For example, the integrated bonding interface  104  prevents water from weeping through the integrated bonding interface  104  and/or through the boundary area  116  between the base structure  102  and the integrated bonding interface. 
     As illustrated above, the plastic component  100  thus provides improved bonding with mortar materials in a tiled wet environment. It is also more durable, more waterproof, and less prone to failure due to movement events and/or prolonged exposure to water than prior art plastic components with multilayered fabrics or coatings. 
     According to an embodiment, the aggregate particles  110  can comprise aluminum oxide, silica sand, blast grit, metallic grit, ceramic grit, shot, combinations thereof, or any other suitable material to form the three-dimensional surface of the integrated bonding interface  104 . The aggregate particles  110  can be angular, rounded, irregularly shaped, or combinations thereof. The aggregate particles  110  can comprise uniform or substantially uniform-size particles. In an embodiment, the aggregate particles  110  can have an average grit size between about 100 and about 300, between about 100 and about 200, or between about 100 and about 150. In other embodiments, the aggregate particles  110  can be uniformly shaped or substantially uniformly shaped particles. In an embodiment, the aggregate particles  110  can be uniformly distributed. In other embodiments, the aggregate particles  110  can include a varying distribution of particle sizes and/or shapes. 
     In the illustrated embodiment, the aggregate particles  110  extend to a depth that terminates in the second polymer material  108  short of the boundary area  116 . Optionally, the aggregate particles  110  can be configured to extend to a depth through the second polymer material  108 , the boundary area  116 , and into the first polymer material  106  of the base structure  102  as shown in  FIG.  7   . This arrangement can help fix the aggregate particles  110  to the plastic component  100 . 
     The aggregate particles  110  may substantially cover the mortar facing surface  112  of the second polymer material  108  of the integrated bonding interface  104 . In an embodiment, the aggregate particles may cover at least 98% of a surface area of the mortar facing surface  112 , at least 95%, at least 90%, at least 80%, or at least 60%. In this manner the aggregate particles  110  provide a surface capable of improved bonding with mortar materials while preventing the passage of moisture that may occur where mortar is insufficiently bonded to a polymer material, as may occur in conventional plastic components. 
     As described in more detail below, the integrated bonding interface can be easily created on almost any surface of a plastic component.  FIG.  8    illustrates a plastic component  200  according to an embodiment having a base structure  202  and an integrated bonding interface  204  comprising a first integrated bonding interface  204 A at an upper surface of the base structure  202 , and a second integrated bonding interface  204 B at a lower surface or underside of the base structure. The integrated bonding interfaces  204 A,  204 B can be similar to the integrated bonding interfaces described above. In an embodiment, the first and second integrated bonding interfaces  204 A,  204 B can be the same or similar. In other embodiments, the first and second integrated bonding interfaces  204 A,  204 B can be configured differently from one another. For instance, the first integrated bonding interface  204 A could have a plurality of aggregate particles  210 A sized and configured to bond with a first type of mortar material, and the second integrated bonding interface  204 B could have a plurality of aggregate particles  210 B sized and configured to bond with a second type of mortar material underlying the plastic component  200 . 
       FIG.  9    illustrates a plastic component  300  according to yet another embodiment having a base structure  302  and an integrated bonding interface  304  located along an entirety of the outer surface of the plastic component  300 . As noted above, the nature of the integrated bonding interface  304  allows it to be formed on almost any surface of the plastic component  300 , without complicating manufacturing of the base structure  302 . 
       FIGS.  10 - 15    illustrate a method of producing or manufacturing the plastic component  400  (shown in  FIG.  15   ) for installation in a tiled wet environment according to an embodiment. A step  401  can include providing a base structure  402  as shown in  FIG.  10   . The base structure  402  can comprise a molded plastic part. For instance, the base structure  402  can comprise a molded square floor drain, a molded circular floor drain, a molded linear floor drain, a molded shower niche, a molded soap holder, a molded drain cover, a molded drain body, a molded drain riser, a molded tile frame, or any other suitable molded plastic part. The base structure  402  can have any suitable shape. The step  401  can include molding the base structure or using an existing molded plastic part of the base structure  402 . The base structure  402  can include a first polymer material  406 . The first polymer material  406  can comprise ABS plastic material, PVC plastic material, CPVC plastic material, or any other suitable polymer material. 
     A step  403  can include applying a formulation  450  to the base structure  402  as shown in  FIGS.  11  and  12   . The formulation  450  can comprise a polymer resin or a plurality of polymer particles  452  in a carrier. In an embodiment, the carrier can comprise a solvent solution and the polymer particles  452  can be suspended in the solvent solution. The polymer particles  452  can comprise ABS particles, PVC particles, CPVC particles, or any other suitable type of polymer particles. Preferably, the polymer particles  452  are the same polymer as the first polymer material  406 . The solvent solution can comprise tetrahydrofuran, Acetone, Methyl Ethyl Ketone, 2-Butanone, Dimethyl Carbonate, and/or any other suitable solvent solution. While the carrier is described comprising a solvent solution, in other embodiments, the carrier may comprise a catalyzed coating, an epoxy, an emulsion or any other suitable carrier for the polymer resin or polymer particles  452 . Step  403  can comprise formulating the formulation  450  for different applications. 
     In an embodiment, the formulation  450  may be configured to harden and/or polymerize at a controlled rate. For instance, the formulation  450  may include an inhibitor and/or a retarder for slowing and/or preventing polymerization under certain conditions. Such an inhibitor may include a reversible terminating agent, stable free radical, or the like that prevents or slows completion of a polymerization reaction, for example at a low temperature, as would be understood by one skilled in the art from the present disclosure. 
     Step  403  can include spraying the formulation  450  onto the base structure  402 . Step  403  can include immersing or dipping the base structure  402  in the formulation  450 . Step  403  can include painting the brushing the formulation  450  onto the base structure  402 . Step  403  can include controlling the viscosity of the formulation to facilitate application of the  450  on the base structure  402 . For instance, the ratio between the solvent solution and polymer particles  452  can be selected to vary the viscosity of the formulation  450  to facilitate application of the formulation  450  on the base structure  402 . Optionally, step  403  can include varying the temperature of the formulation  450  to control flashing of the solvent solution and/or a rate of polymerization of the polymer particles  452 . As discussed below, this beneficially provides more time for the application of a plurality of aggregate particles before the solvent solution vaporizes and before polymerization of the polymer particles  452  causes the formulation  450  to harden or seal. Step  403  can include the solvent solution of the formulation  450  softening and/or dissolving the first polymer material  406  of the base structure  402 , which, in turn, makes polymer molecules or chains from the first polymer material  406  available for molecular bonding or cross-linking with the polymer particles  452 . When this occurs, the polymer molecules or polymer chains are free to move in the solvent solution and can mingle with other polymer molecules or polymer chains. 
     A step  405  can include applying a plurality of aggregate particles  410  to the formulation  450 . Step  405  can include applying the aggregate particles  410  after the formulation  450  has been applied to the base structure  402  as shown in  FIGS.  13  and  14   . The aggregate particles  410  can comprise aluminum oxide, silica sand, blast grit, metallic grit, ceramic grit, shot, combinations thereof, or any other suitable material to form a three-dimensional surface. The aggregate particles  410  can be angular, rounded, irregularly shaped, or combinations thereof. The aggregate particles  410  can comprise uniform or substantially uniform-size particles. In other embodiments, the aggregate particles  410  can be uniformly shaped or substantially uniformly shaped. In an embodiment, the aggregate particles  410  can be uniformly distributed. In other embodiments, the aggregate particles  410  can include a varying distribution of particle sizes and/or shapes. 
     Step  405  can include applying the aggregate particles  410  to the formulation  450  while the formulation  450  is wet or in a liquid state. For instance, step  405  can include varying the temperature of the formulation  450  to control flashing of the solvent solution, which, in turn, allows for the application of the plurality of aggregate particles  410  before the formulation  450  hardens. In an embodiment, the formulation  450  may be applied to the base structure  402  at a temperature at or below 5° C., at or below 2° C., or at or below 0° C., and the aggregate particles  410  may be applied to the formulation  450  while the formulation is at or below 5° C., at or below 2° C., or at or below 0° C. In like manner, the aggregate particles  450  and/or the base structure  402  may be maintained at or below 5° C., at or below 2° C., or at or below 0° C. during steps  403  and/or  405 . 
     In a further embodiment, the formulation  450  may be applied to the formulation  450  during an induction period of a chemical reaction, for example an induction period caused by an inhibitor or retarder at predetermined temperatures or during a period of the reaction controlled by a limited availability of reactants. 
     One or both of steps  403  and  405  may be performed in a temperature- and/or atmosphere-controlled environment in order to control a polymerization rate of the formulation  450 . For instance, application of the formulation  450  and/or application of the aggregate particles  410  may be performed in a freezer. 
     Step  405  can include applying the aggregate particles  410  to the formulation  450  while the formulation  450  is in a liquid state and the aggregate particles  410  are dry. Step  405  can include applying the aggregate particles  410  to the formulation  450  such that the aggregate particles  410  are partially embedded in the formulation  450 . Step  405  can include controlling the viscosity of the formulation  450  to control the embedded depth of the aggregate particles  410  in the formulation  450 . 
     Step  407  can include hardening the formulation  450  to form an integrated bonding interface  404  on the base structure  402  through cross-linking and/or polymerization of the polymer particles  452  of the formulation  450 . Like other embodiments, the integrated bonding interface  404  can include a second polymer material  408  comprising the polymer particles  452  molecularly bonded to each other and to the first polymer material  406  of the base structure  402 , and the aggregate particles  410  partially embedded in a mortar facing surface  412  of the second polymer material  408 . The first polymer material  406  and the second polymer material  408  are preferably the same polymer material. For instance, both can be ABS plastic material. In other embodiments, both can be PVC plastic material. 
     Step  407  can include curing the formulation  450  with heat or ultraviolet light. For instance, where the formulation  450  comprises an epoxy it may be cured with heat to make the integrated bonding interface  404  more heat and/or chemical resistant. Step  407  can include varying a temperature of the formulation  450  such that the solvent solution flashes and the second polymer material  408  hardens to form the plastic component  400  with the integrated bonding interface  404 . 
     Step  407  can include a waiting a period of time for the formulation to harden. For instance, step  407  can include waiting a period of time for at least part or substantially all of the solvent solution to move out of the formulation  450  into the environment, which, in turn, causes the polymer molecules or chains to lose their mobility and forms the second polymer material  408  having a hardened configuration bonded to and/or entangled with the polymer molecules or chains of the first polymer material  406 . Step  407  can include using additives to harden the formulation and form the integrated bonding interface  404 . 
     It will be appreciated that the second polymer material  408  can have a different crystallinity than the first polymer material  406 . For instance, the crystallinity of the second polymer material  408  can be different than the crystallinity of the first polymer material  406  because the second polymer material  408  is processed or formed independently from the first polymer material  406  of the base structure  402 . 
     In a varying embodiments, steps  403  and  405  may be performed in reverse order. In such an embodiment, an amount or location of the formulation  450  applied to the aggregate particles  452  on the base structure  402  may be reduced or otherwise controlled, such that the formulation  450  polymerizes or hardens in such a way as to preserve exposure of the aggregate particles  452  as the mortar facing surface  112  and to result in contact between the first polymer material and the second polymer material. For this purpose, a chemical reaction or polymerization of the formulation  450  may be controlled by temperature, an inhibitor, a retarder or the like until the formulation  450  settles about the aggregate particles  452  in a preferred manner. 
     It will be appreciated that one or more of the foregoing steps can be omitted or combined with other steps. Further, as noted above, the carrier of the formulation  450  can comprise catalyzed coatings, emulsions, epoxies, solvent solutions, and/or any other suitable carrier for the polymer resin or particles. The integrated bonding interface  404  can thus be easily formed on the plastic component  400  without modification and/or interference with the molding of the base structure  402  or plastic component  400 , beneficially simplifying production of the plastic component embodiments. 
     As seen in  FIG.  15   , the aggregate particles  410  partially embedded in the second polymer material  408  form a three-dimensional surface for improved bonding with mortar and other materials. In addition, the molecular linking or bonding between the first and second polymer materials  406 ,  408  beneficially prevents the integrated bonding interface  404  from separating from the base structure  402 , which, in turn, reduces the likelihood of the formation of pathways for water to pass or escape between the base structure  402  and the integrated bonding interface  404 . It also is less prone to separation and failure due to movement events than prior art drain systems. Further, the integrated bonding interface  404  is fully submersible in water without the risk of degradation of the integrated bonding interface  404  because the molecular bonding between the first and second polymer materials  406 ,  408  makes the integrated bonding interface  404  integral to the base structure  402 . This is beneficial because prior art drain components with surface coatings or fabric faces are known to breakdown over time and/or separate when repeatedly or constantly submersed in water. 
     In addition, because the base structure  402  and the integrated bonding interface  404  are sealed together at the boundary area  416  via the molecular bonding, the boundary area  416  is also waterproof, preventing or reducing the likelihood of water getting between the base structure  402  and the integrated bonding interface  404 . For example, the integrated bonding interface  404  prevents water from weeping through the integrated bonding interface  404  and/or through the boundary area  416  between the base structure  402  and the integrated bonding interface. 
     As illustrated above, the plastic component  400  thus provides improved bonding with mortar and other materials in a tiled wet environment. It is also more durable, more waterproof, and less prone to failure due to movement events and/or prolonged exposure to water than prior art plastic components with multilayered fabrics or coatings. 
     The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting. For instance, while the plastic components are described for use in tiled wet environments, in other embodiments, the plastic components can be configured for use in any environment where the plastic component is adapted to bond with a cementitious material and is exposed to water. Additionally, the words “including,” “having,” and variants thereof (e.g., “includes” and “has”) as used herein, including the claims, shall be open ended and have the same meaning as the word “comprising” and variants thereof (e.g., “comprise” and “comprises”).