Apparatuses and methods for producing a shower tray
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Solution Overview
Problem
The challenge in manufacturing shower trays lies in creating a contoured surface with a desired slope in a cost-effective manner, as existing methods rely on expensive computer-controlled machinery and complex 3D modeling, making it difficult to achieve a uniform perimeter depth and comply with varying shower sizes and drain locations.
Innovation Solution
A method involving a shower tray blank with score cuts and deflection techniques using spacers and forces to form a contoured surface without the need for CNC machines, allowing for a uniform depth and desired slope, achieved through scoring and cutting with a hot wire cutter or other tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive computer-controlled machinery and complex 3D modeling are used, then manufacturing precision of the contoured surface is improved, but manufacturing cost increases
Solution Approach 1:
The contoured surface is created through a two-stage process: first scoring the blank to create controlled fracture lines, then deflecting the blank to form the contour. This segmentation of the forming process eliminates the need for expensive CNC machinery while achieving the desired precision.
Solution Approach 2:
Score cuts are made in the shower tray blank before deflection to pre-establish the regions where the material will bend during the deflection process. This preliminary action guides the subsequent deflection to achieve the precise contoured shape without requiring complex computer-controlled machinery.
2Manufacturing precision
If complex 3D modeling software and computer-controlled machinery are used, then manufacturing precision is improved, but productivity decreases due to increased production time
Solution Approach 1:
The manufacturing process is divided into simple, sequential steps: scoring the blank, deflecting it to form the contour, and cutting. Each step is straightforward and can be performed with simple tools, significantly reducing production time compared to complex CNC operations while maintaining precision.
Solution Approach 2:
The method changes the physical state and geometry of the blank through controlled deflection after scoring. By applying deflection forces to the scored blank, the material naturally forms the desired contoured shape, achieving precision without time-consuming computer-controlled machining.
3Ease of manufacture
If standard shower tray manufacturing methods are used, then ease of manufacture is maintained, but adaptability to varying shower sizes and drain locations deteriorates
Solution Approach 1:
Score cuts are strategically positioned at specific locations on the blank corresponding to the desired drain location and shower dimensions. This localized scoring approach allows each tray to be customized for varying shower sizes and drain positions while maintaining the simplicity of the overall manufacturing process.
Solution Approach 2:
The score cuts are pre-positioned according to the specific shower configuration requirements before deflection. This preliminary action enables the blank to be adapted to various shower sizes and drain locations through a simple deflection process, maintaining manufacturing ease while achieving high adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs and time while maintaining high-quality shower trays with uniform perimeter edges and a contoured surface that slopes effectively to the drain, addressing the limitations of existing methods.
Implementation Method 1
cutting with a hot wire cutter
Implementation Method 2
deflecting the shower tray blank at the drain location relative to a shower tray perimeter
Data Source
AI summary
The method of producing a shower tray using a shower tray blank is disclosed. The method may comprise identifying a drain location on the shower tray blank. The method may further comprise deflecting the shower tray blank at an internal location relative to a shower tray perimeter of the shower tray blank along the depth dimension to a deflected state. The method may also comprise cutting the shower tray blank along a plane generally perpendicular to a depth dimension of the shower tray blank when the shower tray blank is in the deflected state to form the shower tray and a discarded portion. An apparatus for producing a shower tray is also disclosed.