Method for manufacturing a prefabricated shower module

1. A method of manufacturing a leak-proof shower module by injection molding, the shower module suitable for use in constructing a tiled shower, the method comprising:

providing a tool for creating the leak-proof shower module, the tool including a cavity portion and a core portion which, when mated together, define a volume corresponding to a shape of the leak-proof shower module to be formed;

inserting at least one drain aperture form into the volume at a location where a drain aperture is to be formed;

injecting a polymeric material into the volume to produce the leak-proof shower module; and

removing the leak-proof shower module from the volume while retaining the at least one drain aperture form in place;

prior to providing the tool for creating the leak-proof shower module, creating indentations in the tool corresponding to one or more support ribs of the shower module to be formed.

2. The method of claim 1 , wherein the at least one drain aperture form contains a first portion having a first outer diameter and a second portion having a second outer diameter, wherein the first outer diameter is greater than or equal to the second outer diameter.

3. The method of claim 1 , further comprising the step of:

cooling the leak-proof shower module while retaining the form.

4. The method of claim 1 , further comprising the steps of:

clamping the leak-proof shower module to a rigid surface such that the module is prevented from flexing and the drain aperture rests in a hole in the rigid surface; and

cooling the leak-proof shower module while retaining the form.

5. The method of claim 1 , further comprising the step of:

coating a bottom surface of the drain wall with a fire-retardant material.

6. The method of claim 1 , wherein the step of injecting polymeric material includes:

injecting the polymeric material into the tool such that the polymeric material flows in a direction parallel to at least one of the plurality of support ribs.

7. The method of claim 1 , wherein the step of injecting polymeric material includes:

injecting the polymeric material into the volume such that the polymeric material flows in a direction which is at an angle of 90° or less to any support rib of the one or more support ribs.

8. The method of claim 1 , wherein the step of injecting polymeric material includes:

injecting the polymeric material into the volume such the polymeric material flows in a direction unimpeded by at least one support rib of the plurality of support ribs.

9. The method of claim 1 , further comprising the steps of:

prior to injecting the polymeric material into the tool, placing at least one insert into the volume corresponding to sidewall of the leak-proof shower module to be made, thereby preventing the polymeric material form filling a portion of the volume which is occupied by the insert to thereby result in a sidewall having a height that is less than a height that said sidewall would have had if the insert had not been used.

10. The method of claim 1 , further comprising the steps of:

prior to injecting a polymeric material into the volume, placing at least one insert into volume corresponding to an end portion of the shower module, thereby preventing the polymeric material from filling a portion of the volume which is occupied by the insert to thereby result in a shower module that has one or both of its length and width dimensions smaller than a length and/or width dimension the shower module would have had if the insert had not been.

11. The method of claim 1 , further comprising the steps of:

prior to injecting the polymeric material into the volume, providing a raised tab in the tool along a peripheral portion of the corresponding to a sidewall of the leak-proof shower module to be formed, thereby creating a fatigue line in the leak-proof shower module located at a height appropriate for a portion of the sidewall to be removed to allow attachment of a modular curb to the sidewall.

12. The method of claim 11 , further comprising the steps of:

detaching a portion of the sidewall from the shower module along the fatigue line to produce a remaining sidewall portion; and

attaching a modular curb in registry with the remaining sidewall portion.

13. The method of claim 1 , further comprising the steps of:

cutting at least one sidewall along a length of the sidewall at a height suitable for attaching a modular curb to produce remaining portion; and

attaching a modular curb in registry with the remaining sidewall portion.

14. The method of claim 1 , further comprising the step of:

cutting at least one side wall along at least a portion of the sidewall at a suitable height to permit the attachment of at least one of an ADA compliant curb and an ADA compliant curbless entry.

15. A method of manufacturing a leak-proof shower module by injection molding, the shower module suitable for use in constructing a tiled shower, the method comprising:

providing a tool for creating the leak-proof shower module, the tool including a cavity portion and a core portion which, when mated together, define a volume corresponding to a shape of the leak-proof shower module to be formed;

inserting a prefabricated drain assembly into the volume at a location where a drain aperture is to be formed;

injecting a polymeric material into the volume, thereby affixing the drain assembly within the shower module to produce an integrated shower module and prefabricated drain assembly;

removing the integrated shower module and prefabricated drain assembly from the tool; and

allowing the integrated shower module and prefabricated drain assembly to cool;

prior to providing the tool for creating the leak-proof shower module, creating indentations in the tool corresponding to one or more support ribs of the shower module to be formed.

16. The method of claim 15 , wherein the step of injecting polymeric material includes:

injecting the polymeric material into the tool such that the polymeric material flows in a direction parallel to at least one rib of the one or more support ribs.

17. The method of claim 15 , wherein the step of injecting polymeric material includes:

injecting the polymeric material into the volume such that the polymeric material flows in a direction which is at an angle of 90° or less to at least one rib of the one or more support ribs.

18. The method of claim 15 , wherein the step of injecting polymeric material includes:

injecting the polymeric material into the volume such the polymeric material flows in a direction unimpeded by at least one rib of the one or more support ribs.

19. The method of claim 15 , further comprising the steps of:

prior to injecting the polymeric material into the tool, placing at least one insert into the voided corresponding to a sidewall of the leak-proof shower module be made, thereby preventing the polymeric material from filling a portion of the volume which is occupied by the insert to thereby result in a sidewall having a height that is less than a height that said side wall would have had if the insert had not been used.

20. The method of claim 15 , further comprising the steps of:

prior to injecting the polymeric material into the volume, placing at least one insert into the volume corresponding to an end portion of the shower module, thereby preventing the polymeric material from filling a portion of the volume which is occupied by the insert to thereby result in the shower module that has one or both of its length and width dimensions smaller than a length and/or width dimension the shower module would have had if the insert had not been used.

21. The method of claim 15 , further comprising the steps of:

prior to injecting the polymeric material into the volume, providing raised tab in the tool along peripheral portion of the volume corresponding to a sidewall of the leak-proof shower module to be formed, thereby creating a fatigue line in the leak-proof shower module located at a height appropriate for a portion of the sidewall to be removed to allow attachment of a modular curb to the sidewall.

22. The method of claim 21 , further comprising the steps of:

detaching a portion of the sidewall from the shower module along the fatigue line to produce a remaining sidewall portion; and

attaching a modular curb in registry with the remaining sidewall portion.

23. The method of claim 15 , further comprising the steps of:

cutting at least one sidewall along a length of the sidewall at a height suitable for attaching a modular curb to produce a remaining portion; and

attaching a modular curb in registry with the remaining sidewall portion.

24. The method of claim 15 , further comprising the step of:

cutting at least one side wall along at least a portion of the sidewall at a suitable height to permit the attachment of at least one of an ADA compliant curb and an ADA compliant curbless entry.

25. The method of claim 15 , further comprising the steps of:

attaching a drain reinforcing structure to the drain assembly to form an interference fit between an opening defined by the reinforcing structure and the periphery of the prefabricated drain assembly, the drain reinforcing structure laying in a substantially horizontal plane within the volume.