Interlocking Modular Shower Pan for Fast Custom Drain Slope Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional shower pan installations require extensive labor and are limited to standard sizes, necessitating pre-sloping and the presence of a plumber for proper drainage, which is inefficient and inflexible.
Innovation Solution
A modular shower pan system comprising interlocking polygon panels with a pre-selected sloped top surface and interlocking profile, allowing for customizable installation without the need for pre-sloping or a plumber, using a computer-calculated slope and adhesive bonding for rapid assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional mortar-based shower pan systems are used, then proper drainage slope can be achieved, but extensive labor and time are required for installation
Solution Approach 1:
The shower pan is divided into multiple pre-sloped panels that can be independently manufactured and quickly assembled. Each panel is pre-formed with the correct drainage slope, eliminating the need for on-site mortar work and manual sloping, thereby reducing installation time and labor while maintaining proper drainage.
Solution Approach 2:
The drainage slope is pre-formed during panel manufacturing rather than being created during installation. This preliminary action ensures correct drainage geometry is built-in before installation, eliminating the time-consuming process of applying and shaping mortar on-site.
2Adaptability or versatility
If standard-sized shower pans are used, then manufacturing is simplified, but customization to fit different shower spaces is limited
Solution Approach 1:
The shower pan system uses modular panels that can be combined in various configurations to create custom-sized and shaped shower floors. This segmentation allows adaptation to different shower spaces while keeping individual panel manufacturing simple and standardized.
Solution Approach 2:
The interlocking panel design serves multiple functions: it provides structural support, creates custom configurations, ensures proper drainage through pre-formed slopes, and simplifies installation. This multi-functionality achieves customization without proportionally increasing system complexity.
3Reliability
If pre-sloping is required for drainage, then proper water flow is achieved, but the process becomes more complex and requires additional steps
Solution Approach 1:
The drainage slope is pre-formed during panel manufacturing, so the sloping action is performed in advance during production rather than during installation. This eliminates complex on-site sloping operations while ensuring reliable drainage geometry is built into each panel.
Solution Approach 2:
The panel manufacturing process directly incorporates the slope as a geometric parameter of the panel itself, rather than adding slope through separate mortar layers. This parameter integration simplifies the overall system while maintaining reliable drainage through built-in angular geometry.
4Reliability
If a plumber is required for installation, then proper drainage connection is ensured, but installation efficiency is reduced
Solution Approach 1:
The shower pan panels are designed with self-aligning and self-leveling features that allow installers to achieve proper drainage geometry without requiring a plumber's specialized skills. The pre-formed slopes and interlocking mechanisms enable the system to self-adjust to correct drainage angles, improving productivity while maintaining connection reliability.
Data Source
AI summary
A modular shower pan includes at least four polygon panels adapted to interlock in side by side relation to form a body. Each panel has a planar bottom surface and a top surface that is sloped based upon a pre-selected drain position on the body.