Wedge Panel Shower Pan Assembly for Flexible Drain Placement
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Solution Overview
Problem
Existing shower pan construction methods are limited by the need for pre-fabricated pans, which restrict size and drain placement, or require specialized skills and materials for custom poured-in-place pans.
Innovation Solution
The use of wedge panels with a closed cell foam core, cut and arranged to form a continuous sloping surface towards the drain, allowing for flexible shower pan dimensions and placement without the need for specialized tools or skills, and enabling curbless installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-fabricated pans are used, then installation is easy, but shower size and drain placement are constrained
Solution Approach 1:
The shower pan is divided into multiple wedge panels that can be individually installed and configured. Each panel is a separate component that can be arranged in different patterns (linear, diagonal, radial) to accommodate various shower sizes and drain placements, combining the ease of pre-fabricated installation with customizability.
Solution Approach 2:
The system allows for dynamic configuration of the shower pan by selecting different panel arrangements and orientations. The wedge panels can be positioned at various angles and configurations to adapt to different spatial requirements and drain locations, providing versatility while maintaining simple installation procedures.
2Adaptability or versatility
If custom poured-in-place pans are used, then shower dimensions and drain placement are flexible, but specialized skills and tools are required
Solution Approach 1:
The wedge panels are designed as disposable or single-use components that are cut to size and discarded after installation, eliminating the need for specialized tools or skills. The panels are simple to cut with standard tools and can be easily disposed of if damaged, replacing the need for complex poured-in-place techniques.
Solution Approach 2:
The system achieves dimensional flexibility by changing the parameters of standard wedge panels through simple cutting operations. Rather than requiring specialized forming techniques, the panels are adapted to specific shower dimensions by cutting them to appropriate sizes and angles, maintaining ease of installation while providing custom fit.
3Adaptability or versatility
If wedge panels are cut and assembled on-site, then shower pan flexibility is achieved, but additional cutting and assembly steps are required
Solution Approach 1:
The wedge panels are designed with specific local qualities - each panel has a predetermined wedge shape with one thin edge and one thick edge, and sloped surfaces at specific angles. This local quality allows panels to be quickly identified and positioned correctly during installation, reducing the complexity of the assembly process while maintaining configuration flexibility.
Solution Approach 2:
The asymmetric wedge shape of each panel, with distinct thin and thick edges and sloped surfaces, provides built-in orientation guidance. The asymmetric design ensures that panels can only be installed in the correct orientation, simplifying the assembly process and reducing errors while allowing for various overall shower pan configurations through different panel arrangements.
Data Source
AI summary
Apparatus and methods for constructing a shower pan. The shower pan is constructed from wedge panels having a foam core and facers on major surfaces of the wedge panels. The wedge panels are cut into portions that fit regions of the shower pan area. The wedge panel portions are placed in the regions such that the sloped upper surfaces of the wedge panel portions collectively form a continuous surface that at all locations slopes downward toward the drain of the shower. Pans for a wide variety of shower shapes and sizes can be constructed. The shower pan may be efficiently constructed on-site, often using common tools and techniques.