Method of manufacturing and installation of prefabricated shower bench and associated shower bench

1. A prefabricated shower bench for installation in a tiled shower, the shower bench comprising:

an upper surface having a plurality of peripheral edges; and

at least three sidewalls, each sidewall having an upper edge and a lower edge, wherein each upper edge is connected along a corresponding peripheral edge of the upper surface, wherein one of the sidewalls includes a setback area along a totality of a lower edge, the setback area having a height greater than a height of a sidewall of a prefabricated shower module, and

wherein the lower edge of each sidewall terminates in a common plane.

2. The shower bench of claim 1 , further comprising:

at least one support rib connected to the upper surface, the support rib extending from at least one sidewall of the plurality of sidewalls and extending downward to terminate coplanar with the lower edge of each sidewall.

3. The shower bench of claim 2 , wherein the at least one support rib runs parallel to a direction of flow of polymeric material during injection molding.

4. The shower bench of claim 2 , wherein the at least one support rib runs at an angle of 90° or less to a direction of flow of polymeric material during injection molding.

5. The shower bench of claim 2 , wherein a direction of flow of polymeric material is unimpeded by the at least one support rib during injection molding.

6. The shower bench of claim 1 , further comprising:

a bottom plate, having a plurality of peripheral edges corresponding to the plurality of peripheral edges of the upper surface, and

wherein the lower edge of each sidewall is connected to a corresponding peripheral edge of the bottom plate.

7. The shower bench of claim 1 , wherein the upper surface is at least one of horizontal and pitched downwards toward the prefabricated shower module when the shower bench is installed adjacent to the sidewall of the shower module such that the sidewall of the shower module resides within the setback area, thereby preventing the weight of the shower bench from resting on the sidewall of the shower module.

8. The shower bench of claim 1 , wherein the upper surface includes a horizontal lip along at least one peripheral edge, the horizontal lip having a height of at least 1 inch and a width of at least ⅜ inches.

9. The shower bench of claim 1 , wherein the upper surface and at least one sidewall define surfaces suitable for retaining at least one of tile, stone, and marble installed thereon.

10. The shower bench of claim 6 , wherein the at least one of tile, stone, and marble are retained using an epoxy containing at least one of 100% resin solids and resin solids mixed with a solvent.

11. The shower bench of claim 1 , wherein the shower bench is constructed using polyurethane reaction injection molding.

12. The shower bench of claim 1 , wherein the shower bench is molded from a polyurethane foam having a density equal to or greater than 12 pounds per foot.

13. The shower bench of claim 1 , wherein the shower bench is molded from a fire-retardant polyurethane foam.

14. A method of installing a tiled shower within an area bounded by a subfloor and stud framing, the subfloor including a plumbing connection communicating with a sewer line, the method including the steps of:

mounting a prefabricated shower bench, adjacent to the stud framing, the shower bench including a bench sidewall having a lower portion that is set back from an upper portion along a length of the bench sidewall;

applying a quantity of adhesive material on the subfloor within the area bounded by the stud framing and the shower bench;

setting a prefabricated leak-proof shower module in place on the subfloor within the area bounded by the stud framing,

the shower module comprising:

at least three module sidewalls, a vertically adjustable drain disposed within a drain aperture, and a floor having a plurality of peripheral edges, the floor being bounded along at least three peripheral edges by the three module sidewalls, each module sidewall extending vertically from the at least three peripheral edges,

whereby said module is positioned on the subfloor such that a first module sidewall is substantially adjacent to the stud framing, a second module sidewall rests under the lower portion of the bench sidewall, an inner surface of the second module sidewall is flush with an outer surface of the upper portion of the bench sidewall, and the drain assembly is in fluid communication with the subfloor plumbing connection;

attaching wallboard to the framing such that a lower edge of the wallboard rests above and is flush with the first module sidewall; and

installing at least one of tile, stone and marble on the wallboard, the module sidewalls, the floor, and the prefabricated shower bench, thereby resulting in a tiled shower.

15. The method of claim 14 , wherein the prefabricated shower bench comprises:

a upper surface having a plurality of peripheral edges; and

at least three bench sidewalls, each bench sidewall having an upper edge and a lower edge, wherein each upper edge is connected along a corresponding peripheral edge of the upper surface,

wherein one of the bench sidewalls includes a setback area along a totality of a lower edge, the setback area having a height greater than a height of the second module sidewall, and

wherein the lower edge of each bench sidewall terminates in a common plane.

16. The method of claim 14 , further comprising:

prior to attaching wallboard to the framing, mounting a prefabricated modular curb to a third module sidewall.

17. A method of manufacturing a prefabricated shower bench for installation in a tiled shower, the method comprising:

providing a tool for creating the prefabricated shower bench, the tool including a cavity portion and a core portion which define a shape corresponding to a shape of the prefabricated shower bench;

placing at least one insert into a voided area of the tool corresponding to at least one of a portion of each sidewall, a upper surface, and a bottom plate of the prefabricated shower bench, thereby preventing the polymeric material from filling the voided area and reducing at least one of the height, width, and length of the prefabricated shower bench;

injecting a polymeric material into the tool to produce the prefabricated shower bench; and

removing the prefabricated shower bench from the tool.