Shaped floor former
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Solution Overview
Problem
Conventional shaped floor formers face challenges when installed in timber floors, particularly due to structural integrity issues and difficulties in maintaining a flat base, which can lead to obstruction and require costly on-site modifications, and the design of waste cover configurations can restrict water flow rates.
Innovation Solution
A shaped floor former with a trimmable flat surface, an integral waterproof membrane, and an offset opening that allows for rotation to avoid obstructions, along with a frame and cover system that provides a flow path for water while maintaining structural integrity and aesthetic consistency with the surrounding flooring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base of the floor former is lowered near the outlet to maintain sufficient thickness for structural integrity, then structural integrity is improved, but the flat installation onto joists is hindered due to obstruction from floor joists
Solution Approach 1:
The floor former transitions from a conventional two-dimensional planar base to a three-dimensional contoured base with varied thickness. The base includes a first region with greater thickness near the outlet and a second region with lesser thickness at the periphery, creating a graduated thickness profile that provides structural integrity where needed while maintaining compatibility with joist installation.
Solution Approach 2:
Different regions of the base are given different thickness properties to serve different functions. The region near the outlet has greater thickness to provide structural integrity and support the waste assembly, while the peripheral region has lesser thickness to facilitate flat installation onto joists and achieve level alignment with the finished floor surface.
2Shape
If the thickness of the floor former is increased at the perimeter edge to achieve level alignment with the finished floor, then aesthetic consistency is improved, but the structural integrity at the outlet region is compromised
Solution Approach 1:
The base employs non-uniform thickness distribution with a graduated profile. The peripheral region has optimized thickness to achieve level alignment with the finished floor surface, while the central region near the outlet has increased thickness to provide the necessary structural integrity for supporting the waste assembly and withstanding loads.
3Reliability
If a conventional flange and cover system is used over the waste outlet, then the waste assembly is retained, but the water flow rate is restricted due to the weir effect created by the flange
Solution Approach 1:
The floor former integrates a recess that directly receives the waste assembly, eliminating the need for a conventional flange and cover system. This extraction of the flange component removes the weir effect that restricted water flow, allowing water to flow directly from the sloping surface into the waste assembly without obstruction, while the recess provides secure retention of the waste assembly.
Data Source
Figure 1~2
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AI summary
The present invention relates to a shaped floor former (1) for installation within solid or timber flooring to provide a waterproof sloping surface for a showering area. The shaped floor former (1) comprising: an outer edge (2) and an opening arranged to receive a waste water assembly. The former (1) further comprises at least one sloping surface (3) for receiving a floor material. The at least one sloping surface (3) extends from the outer edge (2) and slopes towards the opening such that, in use, the at least one sloping surface (3) defines a flow path to direct water towards the opening. The former (1) further comprises an integral waterproof membrane (14).