Wedge Panel Shower Pan for Flexible On-Site Drain Placement

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Solution Overview

Problem

Existing shower pan installation methods are limited by pre-fabricated pans, which restrict size and drain placement, or require specialized skills and tools 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 a drain, allowing for flexible shower pan dimensions and placement without the need for complex measurements or specialized skills, and enabling curbless or curbed installations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If pre-fabricated pans are used, then installation is easy, but shower size and drain position are constrained

Engineering Contradiction:

Improveinstallation easeVSAvoidshower size and drain position flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The shower pan is divided into multiple wedge panels that can be independently installed and configured. Each panel is a separate component with specific geometric properties (wedge shape with varying thickness) that allows them to be assembled in different arrangements to create various shower sizes and drain positions while maintaining ease of installation through standardized components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wedge panels have variable thickness parameters (from thin edge to thick edge) that can be oriented in different directions to achieve different slopes and drain positions. By changing the orientation and arrangement of these panels with fixed geometric parameters, the system achieves versatility in shower configuration without requiring custom fabrication

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If poured-in-place pans are used, then shower dimensions and drain placement are flexible, but specialized skills and tools are required

Engineering Contradiction:

Improveshower dimensions and drain placement flexibilityVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The wedge panels are pre-fabricated with the correct wedge geometry (varying thickness from one edge to the other) and waterproofing properties before installation. This preliminary preparation of components with built-in slope and drainage geometry eliminates the need for on-site forming, specialized pouring skills, and complex tooling, while still achieving flexible shower configurations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The wedge panels are made from inexpensive materials (such as foam core with facers) that can be easily cut and installed without requiring recovery or reuse. This allows for simple field fabrication and installation by standard contractors using basic tools, replacing the need for expensive specialized poured-in-place materials and expertise

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If custom wedge panels are fabricated, then shower pan flexibility is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveshower pan configuration flexibilityVSAvoidpanel fabrication complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The wedge panels are designed with a single varying parameter (thickness) that changes linearly from one edge to the other. This simple geometric parameterization allows the panels to be manufactured using standardized processes and then cut to various sizes and orientations to achieve different shower configurations, maintaining low manufacturing complexity while providing high installation flexibility

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11317767B2Field fabricated shower system

Publication Date: 2022.05.03 JOHNS MANVILLE CORP

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.