Foam Shower Tray with Integrated Slopes for Flat-Surface Installation
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Solution Overview
Problem
Current shower trays made of rigid materials like ceramic, acrylic, or stainless steel are fragile, difficult to form into varied geometries, and require complex and costly manufacturing processes, as well as pre-built slopes for drainage, increasing installation time and costs.
Innovation Solution
An ergonomic foam shower tray with a flat base and integrated slopes for water evacuation, manufactured using a single-step injection molding process with a mixture of polyol and isocyanate, providing elasticity and adaptability to user footprints, and allowing installation on flat surfaces without pre-built inclines or recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid materials (ceramic, acrylic, stainless steel) are used for shower trays, then structural strength is improved, but fragility against impacts and difficulty of forming varied geometries worsen
Solution Approach 1:
The patent changes the material parameter from rigid (ceramic, acrylic, stainless steel) to flexible foam material, enabling easy formation of varied geometries including slopes and drainage channels while maintaining sufficient structural strength for shower tray application
Solution Approach 2:
The patent uses composite foam material that combines flexibility for forming with sufficient strength for structural support, resolving the contradiction between ease of forming and structural integrity
2Strength
If rigid materials are used for shower trays, then manufacturing strength is improved, but machining cost increases due to abrasiveness
Solution Approach 1:
The patent changes the material parameter from abrasive rigid materials to non-abrasive foam material, eliminating machining costs while maintaining manufacturing strength through the molding process
3Ease of manufacture
If flexible materials are used for shower trays, then ease of forming is improved, but pre-built slopes and concavities are required on support floors, increasing construction time and cost
Solution Approach 1:
Instead of requiring the support floor to have pre-built slopes and concavities, the patent inverts the approach by forming the slopes and drainage channels directly in the shower tray itself, eliminating the need for complex support facilities
Solution Approach 2:
The patent merges the shower tray with the drainage structure by forming integrated slopes and drainage channels in the same flexible material, eliminating the need for separate support facility construction
4Adaptability or versatility
If foam material is used for shower trays, then elasticity and adaptability to user footprint are improved, but water evacuation capability may worsen without proper slope design
Solution Approach 1:
The patent applies different properties to different parts of the shower tray: the standing area has elasticity and adaptability to user footprint, while the drainage area has built-in slopes to ensure effective water evacuation toward drainage channels
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
The foam shower tray offers improved ergonomics, increased friction for user safety, reduced manufacturing costs, and simplified installation, with a thicker design ensuring effective water evacuation and preventing leaks, while eliminating the need for complex support structures.
Implementation Method 1
injecting inside the mould a mixture of materials comprising: polyol and isocyanate for obtaining integral polyurethane
Implementation Method 2
foaming agents and a small percentage of polyurethane pigments; waiting for a foaming and reaction time
Implementation Method 3
a series of slopes (3) located on the top surface (3a) opposite to said flat base surface (2); wherein said slopes (3) fall into a drainage channel (4)
Data Source
Figure 1~2
Figure 3~4
AI summary
Ergonomic shower tray (1), comprising: a flat base surface (2); a top surface (3a) opposite to said flat base surface (2), wherein said top surface (3a) comprises on its perimeter area, flat surfaces suitable for the placement of a screen or similar, at least one drainage channel (4) and a drainage area (3b) around said channel comprising at least one slope (3) with a gradient comprised in the range defined between 0.5% and 2% gradient, falling into the at least one drainage channel (4) and an area (3c) adjacent to the drainage area (3b) defined by the remaining flat surface of said top surface (3a) of the shower tray (1); wherein the thickness of the tray is comprised between 1.75 cm and 3.25 cm and wherein the material of said shower tray (1) comprises integral polyurethane defining a plurality of cavities internal to the shower tray (1), providing it with elasticity such that the tray is adaptable to the footprint of a user.