Patent Application
20220079391
Installations of prefabricated bathroom fixtures often do not result in a leveled shower base due to inconsistencies in the building structure to which the fixture is secured. Additionally, such fixtures are typically flexible to some degree and require additional support beneath the fixture base to prevent flexing of the shower base. Flexing of the fixture base may ultimately result in cracking and failure of the fixture.
Manufacturers have sought to resolve these issues by providing supported, pre-leveled shower bases. However, such shower bases rely on the subflooring being level for a level installation, as the integrated pre-leveled supports are provided in reference to an assumed level and consistent surface. As stated above, this is often not the case.
Installation contractors have also attempted to provide a level supported installation by installing supports for the fixture base directly to the subfloor at installation.
For example, contractors commonly embed the fixture base within a newly poured mortar base pressed between the base and the subfloor and secure the fixture base in a leveled position as the mortar cures. However, the mortar layer is prone to separate from the bottom surface of the fixture base as the mortar cures due to compression forces during installation, settling of the mortar, and shrinking of the mortar as it cures. Separation of the mortar from the fixture base results in gaps between the fixture base and mortar layer. The presence of gaps undermines the support for the fixture base and allows the fixture base to flex against the hardened mortar layer and cause scraping noises during use. Repeated scraping over extended use can potentially damage the fixture base.
Use of self-leveling concrete alleviates these issues to some degree but require additional cost and expertise in their application. Moreover, self-leveling concrete is limited in its application to the upper stories of wood-framed structures due to building requirements and fire codes.
It has also been attempted to shim the fixture base during installation to provide supports within the gap between the shower base and frame. However, as for the mortar layer method described above, the piles of foundation material may shift during installation, use, and repair, and therefore do not provide adequate or reliable support for the fixture base.
It is a purpose of the invention disclosed herein to provide improved methods for installations of showers and bathtub bases. It is also a purpose of the invention to provide convenient supports, systems, and fixture bases to aid the improved installation methods.
Compressible supports are disclosed herein for use in installation methods and generally can comprise a support cavity for receiving a curable foundation material. Fixture bases and other fixture installation systems comprising the compressible supports are disclosed herein that incorporate compressible supports into installation methods and offer improvements over conventional installation methods.
Also disclosed herein are methods for installing a fixture base to a building structure comprising providing a compressible support adjacent a building structure, wherein the compressible support comprises a curable foundation material; securing the fixture base to the building structure such that the compressible support contacts the building structure and a surface of the fixture base; and allowing the curable foundation material to cure.
The phrase “a” or “an” entity as used herein refers to one or more of that entity.
References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the context. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, unless otherwise indicated or made clear from the context, the term “or” should generally be understood to mean “and/or” and, similarly, the term “and” should generally be understood to mean “and/or.”
Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein.
The words “about,” “approximately,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described embodiments. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments or the claims. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the embodiments.
In the following description, it is understood that terms such as “first,” “second,” “third,” “upper,” “lower,” “below,” “top,” “bottom,” and the like, are words of convenience and are not to be construed as implying a positional or chronological order or otherwise limiting any corresponding element unless expressly stated otherwise.
The information that follows details various embodiments of the disclosure. For the avoidance of doubt, it is specifically intended that any particular feature(s) described individually in any one of these paragraphs (or part thereof) may be combined with one or more other features described in one or more of the remaining paragraphs (or part thereof). In other words, it is explicitly intended that the features described below individually in each paragraph (or part thereof) represent aspects of the disclosure that may be taken in isolation and/or combined with other aspects of the disclosure. The skilled person will appreciate that the claimed subject matter extends to such combinations of features and that these have not been recited in detail here in the interest of brevity.
As defined herein, the term “compressible” generally encompasses those structures and materials that can accommodate a compression force by altering a dimension of the structure. While it may be technically accurate to consider all structures as compressible to a degree, for the purposes of this disclosure compressible will refer to those structures having a dimension able to be deformed by at least about 5% without causing damage to the structure. Compressible supports also encompass repeatedly compressible structures that include materials able to be compressed by a compression force as defined herein and expand to their original dimensions or a portion thereof upon relief of a compression force. In some aspects, the repeatedly compressible structures can receive a compression force in a range from 1 psi to 100 psi, and expand to at least 70%, at least 80%, at least 90%, or at least 95% of its original dimension upon relief of the compression force.
As defined herein, the term “curable” in reference to a foundation material, or material in general, refers to a material that exists in a first amorphous state (e.g., liquid, gel, particulate flow) before hardening into a structure having fixed dimensions. In this sense, mixed cement can be considered as a curable foundation material in its mixed state, and as a cured foundation material once hardened into a fixed dimension. Generally, the curing of curable foundation materials contemplated herein represent an irreversible chemical change or physical process (i.e. formation of a durable lattice structure). However, in certain aspects, the curable materials can encompass materials that undergo a reversible transition, where the material has fixed dimensions under conditions typical of installation and use. Water, therefore, may not be considered a curable foundation material by the context of this disclosure, as frozen water does not persist at room temperature. In contrast, thermoplastic polymers may be considered as a curable foundation material upon heating to its melting point, as the melted polymer will return to a solid state with fixed dimensions at room temperature.
With respect to “filling” an internal cavity, the term “filled” as referred to herein means filled to any degree that prevents disruptions in continuity of the foundation material along the height dimension of the cavity.
Cavities are described herein as retaining the foundation material to support the fixture base. For the purposes of this disclosure, a “cavity” refers to gaps within a three-dimensional profile of the support having a volume of at least 1 mL. In this sense, the cavities as referred to throughout the specification do not encompass microspheres having a very small internal volume (e.g., ˜μL) such as are commonly present within foamed materials.
The information that follows describes embodiments with reference to the accompanying figures, in which preferred embodiments are shown. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein.
Compressible supports are disclosed herein that address issues of conventional installations.
More generally, the compressible supports disclosed herein can be compressible and/or expandable against a compression force. Repeatedly compressible supports allow the support to largely return to its original shape following a dynamic compression load while the foundation material cures. In this manner, flexing of the bottom surface of a fixture base during installation when the foundation material is not cured and malleable, does not cause the foundation material to lose contact with the fixture base. Rather the foundation material is maintained against the fixture base during dynamic compression forces applied to the fixture base during installation. After installation of the fixture base is complete, the foundation material can be allowed to harden while the compressible support maintains the foundation material against the fixture base, without gaps resulting from the dynamic compression forces.
Supports contemplated herein can be at least partially compressible by reducing at least one dimension (e.g., height) upon application of a compression force to the compressible support. It is also contemplated that the compressible support can resist compression beyond a certain amount of compression, or on the application of a compression force that exceeds a certain load maximum. For instance, the compressible support can be compressible to a range of not more than 40%, 50%, 60%, 70%, 80%, 90%, or 95% of its uncompressed height. In other aspects, the compressible support may be able to accept a compression force (by compression) in a range from 1 to 100 psi, from 1 to 50 psi, from 1 to 20 psi, from 1 to 10 psi, from 1 to 5 psi, or from 0.1 to 10 psi.
In embodiments wherein the compressible support is expandable against the compression force, the support can be capable of withstanding any compression force, or amount of compression disclosed above, to any portion of the original dimension of the support. In certain embodiments, the support may be returned to at least 40%, at least 50%, at least 60%, at least 80%, at least 90%, at least 95%, or at least 100% of its original height after relief from the compression force. Certain aspects may be repeatedly compressed by a compression force and expanded upon relief of the force for any number of repetitions and duration, as would be understood be a person of ordinary skill in the art.
Compressible supports disclosed herein are not limited to any particular composition, and generally can comprise any material that allows the support to be compressed. In certain aspects, compressible supports contemplated herein can comprise plastics such as vinyls (e.g., polyvinyl chloride), polystyrene, polyethylene, phenolics, silicones, cellulose acetate, and urethanes. In certain embodiments the compressible support can comprise a foamed material, an extruded material, a molded material, or any combination thereof. Where the support comprises a foamed material, the foamed material can comprise a non-porous foam suitable to retain a liquid foundation material within a cavity in the support. It is also contemplated herein that the compressible support may comprise further additives and adjuvants as would be understood by those of ordinary skill in the art. For instance, in certain embodiments, the compressible support can comprise a foamed material comprising microsphere additives to improve and expandability of the foamed material against dynamic and variable compression forces (e.g., during installation). In certain aspects, the compressible supports contemplated herein can comprise a repeatedly compressible, or expandable, material (e.g., a memory foam) that allows the support to fully or partially return to an original shape upon relieving a compression force. Other materials suitable for construction of the compressible support are also contemplated herein, as would be understood by a person of ordinary skill in the art.
Cavities with the supports disclosed herein are not limited to any particular size and generally can take any form that allows the cavity to contain a desired amount of a curable foundation material. In certain aspects, the cavity can have a volume of at least 5 mL, at least 10 mL, at least 25 mL, at least 100 mL, or at least 500 mL. In other aspects, the cavity can have a volume in a range from 1 mL to 1L, from 5 mL to 500 mL, or from 25 mL to 250 mL. In this sense, it may be seen that the cavity can comprise a relatively significant amount of volume within the support. In certain aspects, a ratio of the support volume and the cavity volume can be in a range from about 100:1 to about 1:10. Thus, in certain aspects, the support can approach a cup shape where the cavity in the support represents the major portion of the compressible support.
The shape of cavities in the compressible supports contemplated herein is not limited to a particular shape and generally can comprise any shape suitable to support the foundation material during curing. In certain aspects, cavities contemplated herein can comprise cavities within supports contemplated herein may be cylindrical (e.g., a toroidal cylinder), and extend through the support from one surface to an opposing surface. Cavities contemplated herein may be a rectangular prism. Cavities contemplated herein can have a constant or variable cross-section through the length of the cavity. For instance, cavities contemplated herein may have a square, rectangular, circular, oval, triangular, or star-shaped cross-section at any point along the height of the cavity. In certain aspects the cavity can be shaped such that a bottom portion of the cavity is wider than a top portion of a cavity (e.g., conical, pyramidal).
Supports contemplated herein can comprise a plurality of cavities. In some aspects, the support can comprise at least 4, at least 6, at least 12, or at least 24 cavities. Other aspects can comprise 3 to 18 cavities. Aspects contemplated herein can comprise a plurality of cavities within a single support, the amount of cavities based on the size of the support itself. For instance, supports contemplated herein may have an amount of cavities based on the surface area of the support, e.g., about 1 per 4 in2, about 1 per 8 in2, or about 1 per 12 in2. In this manner a single support may be provided which positions several cavities about the footprint of an intended fixture installation. The cavities may be evenly spaced or provided in reference to the counter of fixture base, as discussed relative to the fixture base installation systems below.
Supports contemplated herein can comprise cavities that extend completely through the support, from a top surface to a bottom surface. In this manner, a curable foundation material can be poured into the support and contact the same surfaces that contact the top and bottom surfaces of the compressible support. Cavities may also extend partially through the support, for instance from a top surface to a midpoint within the support. In such instances, the portion of the support between the opposing surface and the cavity wall can comprise a non-compressible material, such that can resist significant compression forces.
Thus, it can be seen that the compressible supports disclosed herein may receive a repeated, variable, and dynamic compression force, and quickly return to its original shape to support the fixture base in an originally secured and level position. In this manner, the cavity can be repeatedly compressed and expanded to an original position as the foundation material cures, while also limiting the amount of the foundation material required to fill the cavity. Such arrangements can also prevent contact between the foundation material and the surface of the building structure and preventing the foundation material from leaking along the bottom surface of the support. Supports comprising a cavity that does not extend through a bottom surface of the support can also provide more efficient repairs, as the foundation material does not contact the building structure itself. The support can be removed from the building structure without effort, or by relieving a separate attachment means securing the support to the building structure, such as any attachment means described herein.
Further still, the cavity can be an internal cavity enclosed completely within the support. In such aspects, the cavity can be prefilled with a foundation material, the foundation material being activatable during or prior to installation to initiate a curing process. As a non-limiting example, the prefilled foundation material can comprise a polymeric resin and an activator configured to be released within the polymeric resin upon compression of the support and internal cavity. In such aspects, the internal cavity may comprise a capsule within the support, breakable upon compression of the support, the cavity, or both. Similar to supports comprising cavities extending partially through the support, supports contemplated herein comprising internal cavities can comprise a non-compressible supporting portion adjacent each of the top and bottom surfaces of the internal cavity and extending to the bottom and top surfaces of the support, respectively. In this manner, the foundation material can be completely restricted within the support and from contacting the building structure or fixture base to be installed. Still, such embodiments allow the support to be compressed and exert a returning expansion force against the compression force to return the support to an original position once the compression force is relieved, thereby allowing the foundation material to cured in a form that provides complete support to the fixture base.
Securing the support between the building structure and the fixture base can be accomplished by adherence of the foundation material to the individual structures during installation. However, additional and/or separate attachment mechanisms are also contemplated herein. For instance, fasteners (e.g., nails, screws, etc.) can be driven through the support and into the subfloor to retain the support directly in position relative to the subfloor. Clips are also contemplated, to connect the top surface of the support with a complementary feature on the bottom surface of the fixture base, for example. In certain aspects, adhesives can be applied, or pre-applied to the top and bottom surfaces to attach the support to the fixture base and/or building structure, respectively. Certain embodiments also can comprise means for attaching the supports to the building structure, the fixture base, or both. Any other combination of latches, adhesives, fasteners, and the like are also contemplated herein, as would be understood by a person of ordinary skill in the art.
In certain embodiments, the cavity can be configured to retain any foundation material disclosed herein, particularly while in an amorphous liquid or gel form. In certain aspects, the support can comprise a capping seal to seal a portion of the cavity once filled with foundation material. Additionally, or alternatively, the cavity can comprise a cavity liner of different material than the body of the support. Where the foundation material comprises a polymeric material, such cavity liners resistant to dissolving on contact of non-polar substances can protect the structural integrity of the support and ensure the foundation material is contained within the cavity. Further, cavity liners may preserve the volume of the cavity as the foundation material cures, to ensure that the foundation material cures in a position that fully secures and supports the fixture base, and ensuring that no substantial gaps are formed between the building structure and the fixture base throughout the span of the foundation material. In certain aspects of the invention, the cavity may be shaped to allow the cavity to expand horizontally under a vertical compression force, such that the volume of the cavity remains substantially constant throughout compression of the support. As a non-limiting example, the support can comprise compressible foam surrounding a rubber-lined cavity wherein the cavity comprising accordion-shaped walls.
In certain embodiments, a deviation of the volume of the cavity throughout a compression of the support can be less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, or less than about 5% relative to the original volume. Sealing the cavity may also allow the compression force to be transferred from the foundation material within the cavity to the compressible support such that the cavity volume is maintained. Any deviation disclosed herein is contemplated for compressions of the height of no more than 40%, no more than 60%, no more than 80%, no more than 90%, or no more than or at least 95% of the original height of the support.
Generally, fixture base installation systems contemplated herein can comprise a membrane layer and a plurality of the compressible supports of the present invention. Compressible supports of the systems contemplated herein can be the same or different, regarding any of the considerations discussed above (e.g., shape, size, composition, etc.). The membrane layer is not limited to any particular material and can be any that are compatible as an underlayment to the compressible supports and installation processes disclosed herein. In certain aspects, the membrane layer can comprise a top surface configured to receive the compressible supports and a bottom surface configured to seat against the building structure. The membrane layer can comprise a footprint that is substantially equivalent to a fixture base to be installed. In certain aspects, the membrane layer can be a square or rectangular shape.
The membrane layer can be flexible or rigid. The membrane layer can be substantially planar or contoured to a particular shape. As for the compressible supports, the membrane layer can also be somewhat deformable along its bottom surface (opposite the compressible supports) to accommodate irregularities in the building structure. Thus, in certain embodiments, the membrane layer can comprise a cellulosic layer (e.g., paper wood, cardboard, etc.), a felt layer, a silicon layer, a foam layer, or any combination thereof.
Systems contemplated herein can comprise compressible supports fixed to the membrane layer in a permanent or removable manner. The compressible supports may be pre-fixed to the membrane or configured to be attached at the time of installation. For systems comprising removable attachment of the compressible supports, markings may be provided on the membrane layer indicating an advantageous, proper, or preferable arrangement of the compressible supports. Markings on the membrane layer can take any form as would be understood by those of skill in the art, for example cross-hatching, grid overlay, or any other marks at predetermined locations.
It is also contemplated that the systems can be designed to complement existing fixture base designs that are commonly installed. Thus, in certain aspects the top surfaces of any or all of the compressible supports of the systems may be specially contoured to accommodate the contour of a particular fixture base. Such contouring can allow the foundation material within the support to better contact the surface of the fixture base and allow a more even compression of the support. Contouring of the top surfaces of the compressible supports may also provide additional guidance to placement of the fixture base with respect to the compressible support, membrane layer, and building structure.
The membrane layer can be attached to the building structure and can comprise any attachment means as discussed above for securing the membrane layer in position. As a non-limiting example, fasteners driven through compressible supports as mentioned above can also be extended through the membrane layer into a subfloor to retain each in position. Alternatively, fasteners can be driven through the membrane layer separately from the compressible supports.
Fixture bases comprising the compressible supports are also contemplated herein.
Compressible supports can be spaced and arranged to contact the fixture base as discussed above. In certain aspects, the compressible supports may also be removable from the fixture base. For example, recesses within the bottom surface of the fixture base can be shaped to retain a compressible support. Compressible supports may be retained within the recesses by adhesives applied prior to installation, or by snug fit design of the supports and recesses. In certain aspects, supports having a seal or cap along the bottom surface can be filled with foundation material prior to securing to the support to the fixture base. Alternatively, the support can be fixed to the fixture base (e.g., placed within a recess) and the support can be filled in an inverted position as the cavity within the support is filled. After filling the cavity with the foundation material, a cap or seal may be applied to close the cavity, and the fixture base may be returned to an upright position while retaining foundation material within the cavity.
Fixture bases contemplated herein are not limited to any singular type, or group of fixtures, and can be generally any that have a surface capable of flex to some degree, particularly during conventional installation methods. The present invention can thus apply to installation of showers, bathtubs, sinks, tiled surfaces, wash basins, wall mounted devices, and foundation components thereof. Problems of conventional installations noted above can be particularly problematic for fixtures where significant compression forces are applied to a base of the structure during consistent repeated use. In certain aspects, installation of fixture bases can refer to the installation of a shower tray, a bathtub, and foundation components thereof.
Also disclosed herein are methods for installing fixtures in a level and secure manner that is not dependent on the condition of the surface to which the fixture is installed. Methods disclosed herein also can withstand the rigors of installment, i.e., any pressures and adjustments applied to the fixture components during installation. Adjustments and settling during installation often can be the cause of displacing mortar pillars, piles of foundation material, and the like, which result in gaps between the surface of the bath fixture and the mortar support. Gaps created between the support and the fixture surface then allow the fixture surface to flex under application of weight to the surface. Flexing of shower bases and bathtub fixtures is a common issue, and commonly measured as the deflection of the surface under 300 psi, according to the relevant ASTM codes.
Methods are disclosed herein for installing a fixture base to a building structure. Methods contemplated herein can comprise (a) providing a compressible support adjacent the building structure, wherein the compressible support comprises a curable foundation material; (b) securing the fixture base to the building structure, wherein the fixture base is adjacent to the compressible support; and (c) curing the curable foundation material.
The compressible supports of methods disclosed herein refer to any of those disclosed above. As will be understood by those of skill in the art, the building structure is also not limited to any particular material or shape and can be any to which installation of fixture base is desired. The building structure may be in any location within the building. In certain aspects the building structure is on a first, second, third, fourth, or fifth floor of a building. In other aspects, the building structure can be located within a basement, a kitchen, a bathroom, or a mud room, of a building. The building structure can be any portion of the building, such as the wall, ceiling, floor, subfloor, or any finished or unfinished stage of the building structure. The building structure can be in any condition suitable to support the fixture to be installed, and comprise any material such as wood, metal, composites, and the like. As a non-limiting example, building structure can comprise a wooden subflooring within a second story master bathroom. Alternatively, the building structure can be a basement mortar floor.
Providing a compressible support adjacent the building structure can comprise manually placing the compressible support directly on the subflooring. In such aspects, providing the support can further comprise attaching the compressible support directly to the building structure. The compressible support can be attached by any of the attachment means disclosed above. It is also contemplated that the compressible support may be provided as part of an installation systems as described above as comprising a membrane layer and plurality of compressible supports. In such aspects, providing the compressible support adjacent the building structure can comprise, or consist of laying the membrane layer directly upon the building structure. In this manner, the compressible support can be considered adjacent the building structure through contact with the membrane layer. Providing the compressible support can also be achieved by a compressible support (or series of compressible supports) attached to the bottom surface of a fixture base, as disclosed above. As for installation systems comprising a membrane layer, compressible supports can be considered as being adjacent the building structure through contact with any caps, seals, or films present between the compressible support and the building structure.
In certain aspects, providing a compressible support can comprise providing a support prefilled with a foundation material. Alternatively, providing a compressible support can comprise adding a curable foundation material within the cavity of the compressible support. In such aspects the foundation material may be added to the top or bottom of the cavity, as described above for installation systems comprising a membrane layer and fixture bases, respectively. Alternatively, the compressible supports may be filled as positioned directly on the subfloor through a top opening in the cavity. Where the support comprises an internal cavity, the foundation material may be injected, or the cavity may be broken, filled, and resealed. As described above, filling the cavity with foundation material or adding foundation material to the cavity can comprise adding any amount of foundation material to the cavity. In some aspects, adding foundation material can comprise adding an amount of foundation material to the cavity greater than 40%, 50%, 60%, 70%, 80%, 90%, 95%, or 100% of the volume of the cavity.
The curable foundation material is not limited to any particular material and can be any material that is suitable to remain amorphous during the installation phase, and to provide fixed support to the fixture base as it hardens. Curable foundation materials as contemplated herein therefore can include cement, concrete, mortar, thin set, and the like. Curable foundation materials also can include polymeric materials formed by the polymerization of resins as activated by an activator. Polymeric resins can include polyester resins, vinyl resins, and epoxy resins. Activators can generally include peroxides and other radical activators, for example methyl ethyl ketone peroxide. Other resins and activators are also contemplated herein, as would be understood by those of ordinary skill in the art.
Once the compressible supports are provided adjacent the building structure as discussed above, the fixture base can be secured to the building structure as the foundation material cures. In certain aspects, securing the fixture base to the building structure may comprise laying a bottom surface of the fixture base on the top surface of the compressible support(s). Securing the fixture base can further comprise leveling the fixture base, fastening the fixture base to the building structure with fasteners, applying adhesives to the fixture bases, applying caulk compounds within the joints between the fixture base and the building structure, securing additional fixture components to the fixture base, or any combination thereof, and in any order. As for the providing the support adjacent the building structure, securing the fixture base adjacent the compressible support encompasses embodiments where a cap, seal, membrane layer, or a non-compressible member between the support and the fixture base. For the purposes of this disclosure, such installations can be considered adjacent even when not in direct contact, so long as a compression force applied to one element may be efficiently transferred to the adjacent element.
Securing the fixture base as described above can occur within (e.g., less than) a curing time of the foundation material. In some aspects, the curing time of the foundation material can be less than about 8 hours, less than about 4 hours, less than about 2 hours, less than about 1 hour, or less than about 30 min, The curing time can be dependent on the composition of the foundation material, and also can be dependent on environmental conditions (e.g., humidity, temperature) at the time of installation. Thus, it is contemplated herein that curing time can be in a range from 30 min to 8 hours, from 2 hours to 4 hours, or from 1 hour to 12 hours. In certain aspects, it is contemplated that securing the fixture base can be completed much faster than the curing time, e.g., 1 hour, 2 hours, 3 hours, 4 hours less than the curing time, to allow the installer sufficient time before the foundation material cures.
Curing the foundation material can comprise generally any method that transforms the amorphous material into a hardened shape with fixed dimensions. The curing step can occur simultaneously with the securing step disclosed herein, and thus can comprise simply allowing the curing time to lapse. In other aspects, the curing step can comprise the timed release of materials into the foundation material, and or mixing of curing additives into the foundation material. Curing the foundation material also can comprise applying energy to the foundation material, such as in the form of ultraviolet light or heat.
Securing the fixture base can comprise maintaining a compression force between the fixture base and the compressible supports. In this manner, the compressible supports remain partially compressed throughout the installation, and curing time of the foundation material. As a non-limiting example, it is contemplated that the bottom surface of compressible supports secured to a fixture base may extend somewhat beyond (e.g., ⅛ inch, ¼ inch, ½ inch, 1 inch) the fixture base itself. Once the fixture base is secured to the building surface, the compressible supports will remain somewhat compressed to ensure good contact between the compressible support and the building structure and the fixture base.
Methods disclosed herein can provide a level fixture base irrespective of the condition, angle, or irregularities present on a building structure. It is also contemplated that the methods disclosed herein can minimize or eliminate the deflection of the fixture base commonly observed from conventional installations. In certain aspects, deflection of the installed fixture base at 300 lbs, according to ANSI standard testing, can be less than about 10 mm, less than about 5 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.1 mm. In other aspects, the deflection at 300 lbs. can be in a range from about 1 mm to about 25 mm, from about 1 mm to about 10 mm, or from about 1 mm to 5 mm.
This application is a non-provisional application of U.S. Provisional Application No. 63/077,203, filed on Sep. 11, 2020, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63077203 | Sep 2020 | US |
