# US 7,743,562 B2 · Light plastic foam construction element for making shower stalls, bathroom stalls and the like > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,743,562 B2 - Document ID: US7743562B2 - Status: Granted - Kind: B2 - Application number: 11/650,143 - Filed: 2007-01-05 - Published: 2007-07-12 - Granted: 2010-06-29 - Earliest claimed: 2006-01-07 - Inventors: Stephan Wedi - Web page: https://patentgrep.com/patent/US7743562B2 ## CPC - A47K 3/284: {Pre-fabricated shower cabinets} - E04C 2/521: {serving for locating conduits; for ventilating, heating or cooling} - Y10T 428/249953: Composite having voids in a component [e.g., porous, cellular, etc.] - A47K: SANITARY EQUIPMENT; ACCESSORIES THEREFOR, e.g. TOILET ACCESSORIES - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A lightweight plastic foam construction element (1), for use in making shower stalls, bathroom partitions and the like, consists of a plastic foam core (4) with at least one external mortar layer (8) reinforced with fibers. The construction element has wall areas that are reinforced with at least one adhered wall component of more rigid material for the attachment of installation components that extend over the outer surface on an operational, working side of the construction element. The wall components (11) are inserted into a groove (10) cut into the working side, and the groove is sealed on the working side using a foam filler element (12). ## Claims ### Claim 1 A lightweight construction element forming an upright wall for a bathroom shower incorporating plumbing fixtures, said construction element comprising a plastic foam core with at least one external, fiber-reinforced mortar layer and an inner area of the wall that is reinforced with at least one wall component of more rigid material for the attachment of the plumbing fixtures that project out from an inner surface on one side of the lightweight construction element that forms a working side facing the shower area, the improvement wherein said at least one wall component is inserted into a groove cut into said working side of the plastic foam core, wherein the groove is sealed on the working side using a foam filler element in the form of a plastic foam board, wherein the wall component is of a waterproof plastic, and wherein the groove is in the form of a channel cut with a mirror-symmetrical stepped cross-section that narrows toward the inner side, whereby the groove has opposing steps and at least the filler element rests against the opposing steps, thereby hiding the wall component. ### Claim 2 (depends on 1) A lightweight construction element as in claim 1, wherein the wall component is of a plastic whose dimensional alteration after immersion in water for 24 hours is less than 1%. ### Claim 3 (depends on 1) A lightweight construction element as in claim 1, wherein the wall component is of water-resistant particle board or plaster cardboard plate. ### Claim 4 (depends on 1) A lightweight construction element as in claim 1, wherein the wall component is of a non-foamed polyurethane with admixtures of thermoplastics and additives. ### Claim 5 (depends on 1) A lightweight construction element as in claim 1, wherein the lightweight construction element forms a curved section of a round bathroom shower cabinet. ### Claim 6 (depends on 1) A lightweight construction element as in claim 1, wherein the filler element is of foamed plastic, and includes on one side of the same mortar coating as the lightweight construction element. ### Claim 7 (depends on 1) A lightweight construction element as in claim 1, wherein the wall component extends over the entire height of the lightweight construction element. ### Claim 8 (depends on 1) A lightweight construction element as in claim 1, wherein the groove forms a channel with a mirror-symmetrical stepped cross-section that narrows toward the inner side, and wherein the filler element rests against opposing steps in the stepped cross-section. ### Claim 9 (depends on 1) A lightweight construction element as in claim 1, wherein at least one of the wall component and the filler element are attached to the other parts of lightweight construction element. ### Claim 10 (depends on 1) A lightweight construction element as in claim 1, wherein cutouts for water-lines and branch lines are directly embedded into the foam material of the lightweight construction element outside the wall component and outside the filler element. ### Claim 11 (depends on 1) A lightweight construction element as in claim 1, wherein the edges of the lightweight construction element are provided with fastening elements. ### Claim 12 (depends on 11) A lightweight construction element as in claim 11, wherein the edges are provided with slots and the fastening element is a spline element insertable in the slots. ### Claim 13 (depends on 9) A lightweight construction element as in claim 9, wherein said at least one of the wall component and filler element is attached by means of an adhesive. ### Claim 14 (depends on 9) A lightweight construction element as in claim 9, wherein said at least one of the wall component and filler element is attached by means of on or more screws. ### Claim 15 A lightweight construction element forming an upright wall for a bathroom shower incorporating plumbing fixtures, said construction element comprising a plastic foam core having an inner working surface and an outer surface with at least one outer, fiber-reinforced mortar layer, wherein the inner working surface has a groove that has two or more steps and that narrows going into the foam core from the inner working surface; a wall component of material more rigid than the foam core that is positioned in the narrower or narrowest step of the channel to support plumbing that projects through the inner working surface; and a foam filler element in the form of a plastic foam board that is positioned in a step of the channel at the inner surface, seals the channel, and has openings through which plumbing projects, wherein the wall component is of a waterproof plastic and wherein the groove is in the form of a channel cut with a mirror-symmetrical stepped cross-section that narrows toward the inner side, whereby the groove has opposing steps and at least the filler element rests against the opposing steps, thereby hiding the wall component. ### Claim 16 (depends on 15) A lightweight construction element as in claim 15 which is arcuate.