Prefabricated Bathroom Floor Weight Reduction via Lightweight Concrete

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Solution Overview

Problem

Prefabricated bathrooms face challenges with vibration due to uneven floor support and increased weight, which complicates transportation and installation, and existing methods are inefficient in reducing mass and assembly time.

Innovation Solution

The use of lightweight concrete for the floor and walls, with single building panels and threaded sleeves for support, along with corner rails for protection and increased strength, addresses the issues of weight and vibration, and simplifies production and installation by reducing mass and eliminating the need for time-consuming panel transitions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional concrete is used for the floor, then the floor has sufficient strength, but the room module becomes too heavy for efficient transport and installation

Engineering Contradiction:

Improveweight of room moduleVSAvoidstrength of floor

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent changes the material parameter from conventional concrete to lightweight concrete, which has lower density and weight while maintaining sufficient structural strength through optimized composition and reinforcement

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The floor is constructed as a composite structure combining lightweight concrete with steel reinforcement bars, creating a material system that achieves both reduced weight and sufficient strength through the synergistic combination of different materials

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If the floor is supported only at four corners, then installation is simple, but the floor vibrates under load and may permanently yield or break

Engineering Contradiction:

Improveease of installationVSAvoidstability of floor

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The support system is segmented into multiple discrete support points distributed across the floor area, transitioning from four corner supports to numerous distributed supports that reduce span length and prevent vibration while maintaining installation simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent provides more support points than the minimum four corners, using excessive support distribution to ensure the floor does not vibrate or permanently yield under load, while the modular support design keeps installation relatively simple

Inventive Principle:

Principle #16Partial or excessive action

3Ease of manufacture

If multiple construction panels are assembled to form walls, then the walls can be constructed, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improveease of wall constructionVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent merges multiple separate construction panels into a single integrated wall element, eliminating the need for assembly joints and transitions between panels, thereby reducing assembly time and complexity while maintaining wall construction capability

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4467738A1Room module, in particular a prefabricated bath of compact construction

Publication Date: 2024.11.27 BERNHARD BUNGELER

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Figure 2~4

AI summary

The invention relates to a room module, in particular a prefabricated bathroom, for installation in a building with a floor (1), lightweight concrete walls (2) and a lightweight concrete ceiling (3), wherein the floor (1) is made of lightweight concrete.