Unitary Bathroom Using Honeycomb Composite Panels
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Solution Overview
Problem
Unitary bathrooms suffer from insufficient strength, limited decoration options, poor texture, ease of deformation, and short lifespan due to the use of light and thin sheet materials, along with unsafe assembly and peeling issues from aging.
Innovation Solution
A unitary bathroom constructed using aluminum or paper honeycomb composite boards, connected with glass cement and reinforced with polyurethane, glass fiber, and corner braces, allowing for enhanced strength, decoration flexibility, and improved installation and transportation convenience, while reducing weight and extending lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If light and thin sheet material is used for unitary bathroom construction, then weight is reduced and ease of installation is improved, but strength and stiffness are insufficient leading to deformation and short lifespan
Solution Approach 1:
The patent applies composite materials by combining aluminum honeycomb core with surface panels (ceramic, artificial stone, natural stone, aluminum alloy, stainless steel, zinc coated steel plate, fire proof plate, SMC or plastic) to create panels that are both lightweight and high-strength. The honeycomb structure provides exceptional strength-to-weight ratio while the surface panels provide durability and aesthetic properties, resolving the contradiction between light weight and high strength.
2Ease of manufacture
If traditional coating materials are used on bathroom panels, then application is simple, but decoration styles are limited and texture is poor
Solution Approach 1:
The patent changes the fundamental parameter of the panel surface by using entire surface panels made of diverse materials (ceramic, artificial stone, natural stone, aluminum alloy, stainless steel, zinc coated steel plate, fire proof plate, SMC or plastic) rather than coating traditional panels. This provides unlimited decoration styles and textures while maintaining ease of installation through the standardized panel system.
3Ease of manufacture
If traditional panel materials are used for unitary bathroom, then initial cost is lower, but panels are easily deformed and color fades after long time use reducing lifespan
Solution Approach 1:
The patent uses composite materials with inherent durability properties. The aluminum honeycomb structure provides structural stability resistant to deformation, while the surface panels (particularly stainless steel, aluminum alloy, and treated stone materials) provide fade-resistant coloring and surface durability. This extends the lifespan significantly compared to traditional materials while maintaining cost-effectiveness through long-term durability.
Solution Approach 2:
The patent changes the material composition parameters to include fire-proof plates, stainless steel, and treated materials that inherently resist deformation, fading, and aging. These material parameter changes ensure long-term performance and extended lifespan without requiring frequent maintenance or replacement.
4Ease of operation
If traditional assembly methods are used for unitary bathroom, then construction is straightforward, but assembly safety is poor and panels are susceptible to peeling off due to aging
Solution Approach 1:
The patent merges the panel structure into unitary integrated panels where the honeycomb core and surface panels are permanently bonded through co-forming or adhesive bonding. This creates a unified structure that eliminates peeling issues between layers and provides inherent assembly safety through the integrated design, while maintaining ease of installation through the standardized panel system.
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
The bathroom becomes structurally stable, resistant to deformation and aging, with increased strength and stiffness, offering a wide range of coating materials and improved safety features like shock and fire resistance, and reduced maintenance costs.
Implementation Method 1
the side panel, upper back panel, lower back panel, and ceiling are all constructed of aluminum honeycomb composite boards or paper honeycomb composite boards
Implementation Method 2
A female rabbet of the upper back panel is engaged with a corresponding male rabbet of the lower back panel, and they are sealed and connected together through glass cement
Implementation Method 3
The locking plate is installed on the base through screws
Implementation Method 4
The upper back panel and side panels are connected with each other by corner braces
Data Source
AI summary
The present invention is directed to a unitary bathroom which includes an upper back panel, a lower back panel, a base, and side panels all of which are formed by aluminum honeycomb composite boards or paper honeycomb composite boards. The invention also relate to connection among above the upper back panel, lower back panel, base, side panels and ceiling. The unitary bathroom constructed according to the invention is reliable, and structurally stable. The bathroom will not be loosened after long term use. In addition, the unitary bathroom made of aluminum honeycomb composite board is lightweight, strong, and has good stiffness. The coating material may be freely selected from ceramic, artificial stone, natural stone, aluminum alloy, stainless steel, zinc coated steel plate, fire proof plate, SMC and plastic. Moreover, it has strong shock proof ability and high fire proof ability. No deformation and aging will occur after long term use.