Contoured Drain Wall Structure for Warp-Resistant Shower Modules
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Solution Overview
Problem
Existing prefabricated shower modules face issues with uneven cooling during manufacturing, leading to bowing and warping, which affects the pitch and integrity of the shower floor, and limits design options due to the need for specific molds and integrated curbs, making them costly and restrictive in size and installation.
Innovation Solution
The use of polyurethane reaction injection molding with support ribs and a contoured drain wall design to ensure uniform cooling and reduce warping, along with modular components like a prefabricated curb and shower bench that can be customized and easily integrated with the shower module, allowing for improved installation and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding processes are used for prefabricated shower modules, then production can proceed with standard methods, but uneven cooling occurs leading to bowing and warping of the shower floor
Solution Approach 1:
The patent modifies the physical parameters of the molding process by implementing a contoured drain wall design with varying thickness (thinner at top, thicker at bottom) and adding support ribs. These parameter changes enable more uniform cooling distribution during manufacturing, preventing the bowing and warping that occurs with conventional uniform-thickness designs, thereby maintaining shower floor flatness and structural integrity.
2Adaptability or versatility
If integrated curbs are used in prefabricated shower modules, then the shower system is more complete, but design options are limited and costs increase
Solution Approach 1:
The patent separates the curb from the shower module, making them independent components. This segmentation allows the shower module to be manufactured without an integrated curb, enabling greater design flexibility and customization options. The curb can be selected and installed separately based on specific project requirements, reducing complexity constraints while maintaining adaptability.
3Manufacturing precision
If thicker mortar layers are used to form the shower floor, then a sloped surface can be created, but curing time increases significantly
Solution Approach 1:
The patent incorporates the slope formation into the molding process itself rather than requiring subsequent mortar application. The contoured drain wall design with varying thickness creates the desired slope during manufacturing, eliminating the need for thick mortar layers and their associated long curing times. This preliminary action during production significantly reduces the time loss associated with floor curing.
4Manufacturing precision
If custom molds are created for each shower module design, then design specificity is achieved, but manufacturing costs increase
Solution Approach 1:
The patent designs a universal mold that can accommodate multiple shower module configurations through the standardized contoured drain wall design. The varying thickness design and support rib structure serve multiple functions across different module types, allowing a single mold to produce various designs cost-effectively while maintaining design accuracy and precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing time and costs by minimizing warping and bowing, increases design options, and maintains the leak-proof integrity of the shower system, enabling faster and more flexible installation of prefabricated shower enclosures.
Implementation Method 1
the module must cool (e.g., solidify) before being removed from the mold
Implementation Method 2
the module must cool (e.g., solidify) before being removed from the mold
Data Source
AI summary
A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower includes a plurality of sidewalls, a floor bounded along at least one peripheral edge by at least one sidewall extending substantially vertically from the edge, and a drain wall defining a drain aperture and having an outer surface and an inner surface. In one embodiment, the floor slopes toward the drain wall at a pitch equal to or greater than ⅛ inch per foot. A prefabricated drain assembly is integrated into the floor and encased inside the drain wall, or a drain fixture is inserted into the drain aperture after fabrication of the floor. In one embodiment, the maximum thickness of the drain wall, measured from the outer surface to the inner surface, is equal to or less than 1 ½ times the smallest inner diameter.