Inside Corner Backer Board Molding Insert for Rounded Corners
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Solution Overview
Problem
Current methods for forming and installing rounded corners in bathrooms are inefficient due to the difficulty in achieving a smooth finish and the accumulation of grime, soap scum, and hard water deposits in inside corners, which makes cleaning challenging and often results in right-angle corners being preferred over rounded ones.
Innovation Solution
A backer board molding insert with an arcuate portion and laterally extending walls that form a corner edge, designed to fit securely in inside corners, allowing for the installation of rounded corners by nesting in the corner and supporting a backer board for a smooth tile finish, with optional fastening for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If mud or pre-mixed joint compound is used to form rounded corners, then rounded corners can be installed, but the process requires sanding and is harder to achieve a smooth finish
Solution Approach 1:
The molding insert is pre-formed with the rounded corner shape during manufacturing, eliminating the need for on-site shaping. The insert is inserted into the corner and secured, providing an immediate smooth surface ready for tiling without requiring sanding or additional finishing work.
Solution Approach 2:
The molding insert acts as an intermediary component between the wall corner and the tile surface. It provides a pre-formed rounded transition that mediates between the sharp corner geometry and the requirement for a smooth tiled surface, eliminating the need to work with difficult-to-control joint compounds.
2Ease of manufacture
If inside corners are left as sharp right angles, then installation is simpler, but grime, soap scum, and hard water deposits accumulate making cleaning difficult
Solution Approach 1:
The molding insert introduces a curved surface into the corner geometry, replacing the sharp right angle with a rounded transition. This curvature prevents grime and deposits from accumulating in corner crevices while maintaining ease of installation through a simple insert-and-secure process.
3Shape
If rounded corners are installed using traditional methods, then corner shaping is achieved, but the process is time-consuming and labor-intensive
Solution Approach 1:
The rounded corner shape is pre-formed during manufacturing of the molding insert, consolidating what would otherwise be time-consuming on-site shaping work into a single insertion and securing step. This dramatically reduces installation time while maintaining the desired rounded corner geometry.
Data Source
AI summary
An inside corner backer board molding insert is provided. The molding insert includes a body formed by a rigid member. An arcuate portion disposed on a front side of the body extends longitudinally from an upper face to a lower face of the body. The arcuate portion defines a concave surface extending laterally from a first longitudinal edge to a second longitudinal edge. A pair of laterally extending walls extend perpendicularly relative to each other and intersect forming a corner edge disposed on a rear side of the body. The corner edge forms a right angle sized to engage an inside corner of a wall. Opposing sides of the body interconnect the arcuate portion to the laterally extending walls and include a width sized to receive a backer board flush thereagainst. A lip extending outwardly from and edge of the opposing sides provides a support surface for the backer board.