Ribbed prefabricated polyurethane shower module

Abstract

A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower includes a plurality of sidewalls ( 101, 102, 103, 104 ), a floor ( 110 ) and a plurality of ribs ( 120 ) connected to the floor. The floor has an upper surface, a lower surface, and a plurality of peripheral edges and is bounded along at least one peripheral edge by at least one sidewall that extends substantially vertically from the at least one peripheral edge. Each rib extends parallel to, perpendicular to, or at an acute angle to at least one peripheral edge and runs toward at least one drain wall and terminates in an outer edge lying in a common plane. In one embodiment, the upper surface slopes downward toward the drain wall at a pitch of ⅛ inch per foot or greater and each rib extends downward from the lower surface, resulting in a horizontal common plane.

1 . A prefabricated, polyurethane reaction injection molded, leak-proof shower module suitable for use in constructing a tiled shower, the shower module comprising:
 a plurality of sidewalls;   a floor having an upper surface, a lower surface, and a plurality of peripheral edges, wherein the floor is bounded along at least one peripheral edge by at least one sidewall, the at least one sidewall extending substantially vertically from the at least one peripheral edge; and   a plurality of ribs connected to the floor, each rib extending one of parallel to, perpendicular to, and at an acute angle to at least one peripheral edge toward at least one drain wall defining a drain aperture, each rib terminating in an outer edge, and each outer edge laying in at least one common plane.   
   
   
       2 . The shower module of  claim 1 , wherein the upper surface slopes downward from each peripheral edge toward the at least one drain wall at a pitch equal to or greater than ⅛ inch per foot, and
 each rib of the plurality of ribs extends downward from the lower surface, resulting in the at least one common plane extending horizontally.   
   
   
       3 . The shower module of  claim 2 , further comprising:
 a bottom panel connected to the at least one sidewall and the outer edge of each rib.   
   
   
       4 . The shower module of  claim 1 , wherein the lower surface extends in a horizontal plane from each peripheral edge to the at least one drain wall and each rib of the plurality of ribs extends upwards from the upper surface, and wherein the at least one common plane slopes downward from at least one peripheral edge towards the at least one drain aperture at a pitch equal to or greater than ⅛ inch per foot. 
   
   
       5 . The shower module of  claim 1 , wherein each sidewall is connected to the floor in an orientation within 10 degrees of vertical when the shower module is installed. 
   
   
       6 . The shower module of  claim 1 , wherein the largest vertical distance from any outer edge of any rib to at least one of the upper surface and the lower surface is 4 inches or less. 
   
   
       7 . The shower module of  claim 1 , wherein the difference between any two vertical distances measured from any two points on the outer edge of any rib to at least one of the upper surface and the lower surface is 3 inches or less. 
   
   
       8 . The shower module of  claim 1 , wherein
 at least one rib of the plurality of ribs extends upwards from the upper surface and wherein the at least one common plane slopes downward from at least one peripheral edge towards the at least one drain aperture at a pitch equal to or greater than ⅛ inch per foot, and   at least two ribs of the plurality of ribs extend downward from the lower surface, resulting in each outer edge of the at least two ribs laying in a common horizontal plane.   
   
   
       9 . The shower module of  claim 7 , wherein the largest vertical distance from any outer edge of any rib extending from the upper surface to any outer edge of any rib extending from the lower surface is 4 inches or less. 
   
   
       10 . The shower module of  claim 7 , wherein the difference between any two vertical distances measured from any two points on the outer edge of any rib extending from the upper surface to any outer edge of any rib extending from the lower surface is 3 inches or less. 
   
   
       11 . The shower module of  claim 1 , wherein any rib of the plurality of ribs runs parallel to a direction of flow of material during injection molding. 
   
   
       12 . The shower module of  claim 1 , wherein any rib of the plurality of ribs runs at an angle of 90° or less to a direction of flow of material during injection molding. 
   
   
       13 . The shower module of  claim 1 , wherein the plurality of ribs is arranged in at least one of a sunburst pattern, a diamond pattern, and a honeycomb pattern. 
   
   
       14 . The shower module of  claim 1 , wherein the shower module is formed by injecting polymeric material into one or more injection sites of a tool, the tool including a cavity and a core which define a shape corresponding to a shape of the leak-proof shower module; and whereby the polymeric material flows through the tool at one or more angles, each angle being 90 degrees or less to the flow direction of the polymeric material from the one or more injection sites. 
   
   
       15 . The shower module of  claim 1 , wherein the shower module is molded from a polyurethane foam having a density equal to or greater than 12 pounds per cubic foot. 
   
   
       16 . The shower module of  claim 1 , wherein the shower module is molded from a fire-retardant polyurethane foam. 
   
   
       17 . The shower module of  claim 1 , wherein the floor and the at least one sidewall define surfaces suitable for retaining at least one of tile, stone, and marble installed thereon. 
   
   
       18 . The shower module of  claim 17 , wherein the at least one of tile, stone, and marble are retained using an epoxy containing at least one of 100% resin solids and resin solids mixed with a solvent.