Ribbed prefabricated polyurethane shower module

Abstract

A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower includes a plurality of sidewalls (101, 102, 103, 104), a floor (110) and a plurality of ribs (120) connected to the floor. The floor has an upper surface, a lower surface, and a plurality of peripheral edges and is bounded along at least one peripheral edge by at least one sidewall that extends substantially vertically from the at least one peripheral edge. Each rib extends parallel to, perpendicular to, or at an acute angle to at least one peripheral edge and runs toward at least one drain wall and terminates in an outer edge lying in a common plane. In one embodiment, the upper surface slopes downward toward the drain wall at a pitch of ⅛ inch per foot or greater and each rib extends downward from the lower surface, resulting in a horizontal common plane.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The present patent application is related to co-pending and commonly owned U.S. patent application Ser. No. ______, Attorney Docket No. 8540-07003, entitled “Method for Manufacturing a Prefabricated Modular Shower Curb and Associated Modular Shower Curb,”U.S. patent application Ser. No. ______, Attorney Docket No. 8540-07004, entitled “Prefabricated Shower Pan Having Varying Sidewall Heights and Method of Attaching a Modular Curb Thereto,” U.S. patent application Ser. No. ______, Attorney Docket No. 8540-07005, entitled “Improved Drain Wall for a Prefabricated Shower Module,” U.S. patent application Ser. No. ______, Attorney Docket No. 8540-07006, entitled “Improved Method for Manufacturing a Prefabricated Shower Module,” and U.S. patent application Ser. No. ______, Attorney Docket No. 8540-07007, entitled “Method of Manufacturing and Installation of Prefabricated Shower Bench and Associated Shower Bench,” filed on even date with the pres...

AI Technical Summary

Problems solved by technology

Most tile-covered shower enclosures are created using complicated construction methods.

The process of creating the enclosed shower is time-consuming and requires a certain degree of skill in order to maintain the proper pitch and uniformity in shaping the floor.

Irregularities in the pitch of the floor can cause water from the shower not to drain properly or make tiling the shower enclosure difficult.

The liners are also susceptible to punctures or leaks and may be difficult for the installer to properly form square corners at the intersection of the shower sidewalls and floor.

Additionally, the mortar layer used to create the floor is necessarily thick in order to form a sloped surface, therefore the time required for the floor to cure before applying tile may be quite long (e.g., greater than 24 hours).

However, these prefabricated shower modules contain weaknesses in the design which add cost to the final product.

However, the mold or “tool” for creating each unit can be quite expensive, thus a manufacturer generally limits the number of tools for producing each module.

This problem is exacerbated by non-uniform thicknesses of the plastic material throughout the module.

Thus, if the module is removed from the mold before it is completely cooled, areas of the modules having different thicknesses cool at different rates, resulting in bowing across the surface of the floor As a result, severely bowed modules must be discarded, increasing the unit cost for other modules.

Additionally, slightly bowed modules present potential field problems (i) by impacting uniform tile adhesion on the upper surface of the floor of the shower module, (ii) by preventing the lower surface of the floor of the shower module from sitting flush on the subfloor, and (iii) by changing the pitch of the upper floor of the shower module, which causes puddling or ponding of water on the upper floor of the shower module rather than properly pitched draining.

Further, uneven cooling along the drain aperture may result in a misshapen aperture, thereby (i) preventing the installer from acquiring (or hampering his / her ability to acquire) a water-tight seal around the drain fixture, and (ii) interfering with the insertion of the drain fixture into the drain aperture.

Uneven cooling along the drain assembly (i) may prevent a proper connection (e.g., a water-tight connection) between the drain assembly and the shower module, (ii) may warp the drain aperture at the top of the drain assembly, thereby interfering with the insertion of the drain top into the top of drain assembly, and (iii) may warp the drain aperture in the bottom of the drain assembly, thereby interfering with the connection of the drain assembly to the plumbing line.

Further, each size module requires a specific mold, thus the manufacturer is forced to limit the selection of available modules to a few standard sizes.

The design options for a customer (e.g., an architect, a designer, a contractor, an installer, or homeowner) desiring to implement a prefabricated shower module are therefore limited to a few set arrangements.

Additionally, features such as shower benches or ledges must still be constructed by hand, or added in a piece-meal fashion, thereby compromising the leak-proof integrity of the prefabricated shower module.

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