Modular Sanitary Support Structure for Weight Reduction and Tolerance Control
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Solution Overview
Problem
Ceramic sanitary articles are heavy, difficult to install, and have manufacturing tolerances that complicate mounting on walls, while also being costly and requiring complex manufacturing processes.
Innovation Solution
A lightweight, modular support structure with connection elements for design and functional components, allowing for easy assembly and integration of features like seat height adjustment and improved load distribution, using additive manufacturing for precise construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic sanitary articles are manufactured using traditional casting processes, then they achieve sufficient strength and durability, but they become heavy and difficult to install
Solution Approach 1:
The sanitary article is divided into multiple components: a supporting structure (mounting frame) and a sanitary basin. The supporting structure bears the load and provides mounting functionality, while the basin can be made lighter. This segmentation allows the heavy-duty structural functions to be separated from the sanitary functions, enabling weight reduction in the basin without compromising overall strength.
Solution Approach 2:
The supporting structure can be manufactured using composite materials or metal frameworks instead of traditional solid ceramic. This allows achieving the required mechanical strength and mounting capability with significantly reduced weight compared to solid ceramic construction.
2Duration of action of stationary object
If ceramic sanitary articles are manufactured using traditional casting processes, then they achieve sufficient durability, but the manufacturing process becomes complex and costly
Solution Approach 1:
By dividing the sanitary article into a supporting structure and a basin, each component can be manufactured using simpler, more cost-effective processes. The supporting structure can be produced using modular frameworks or injection-molded plastics, while the basin can be manufactured using lighter-weight materials and simpler molding techniques, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The supporting structure serves multiple functions: providing structural support, enabling wall mounting, and potentially integrating mounting elements for additional features. This multi-functionality reduces the need for separate components, simplifying the manufacturing process while maintaining durability.
3Strength
If ceramic sanitary articles are manufactured with traditional processes, then they achieve sufficient strength, but manufacturing tolerances vary making installation difficult
Solution Approach 1:
The supporting structure is designed as a separate modular component with standardized mounting interfaces. This segmentation allows the mounting frame to be manufactured with precise, standardized tolerances using modern manufacturing processes, while the basin can be manufactured separately. The modular design with standardized connection interfaces ensures consistent installation quality regardless of variations in individual component manufacturing.
Solution Approach 2:
The supporting structure can be manufactured using modern processes such as injection molding or precision metalworking, which offer tighter and more consistent tolerances compared to traditional ceramic casting. This parameter change in manufacturing process enables more precise control over dimensions and mounting hole positions, facilitating easier and more consistent installation.
4Duration of action of stationary object
If ceramic sanitary articles are manufactured using traditional methods, then they achieve sufficient durability, but production costs increase and automation is limited
Solution Approach 1:
Dividing the sanitary article into a supporting structure and basin allows each component to be manufactured using highly automated processes. The supporting structure can be produced using automated injection molding or metal fabrication, and the basin using automated molding or forming processes. This segmentation enables greater automation compared to traditional monolithic ceramic casting, increasing production efficiency while maintaining durability through specialized manufacturing processes for each component.
Data Source
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AI summary
The invention relates to a support structure (1) for a sanitary article (2), which forms a receptacle (3) for a sanitary basin (20) and has connection elements (4) for a plurality of design and/or functional components (5) of the sanitary article (2). A sanitary article set (14), a toilet basin (15), and suitable uses of the support structure (1) are further described.