Prefabricated Shower Bench with Setback for Modular Integration
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Solution Overview
Problem
Conventional methods for manufacturing prefabricated shower modules face challenges such as uneven cooling leading to bowing, limited design options due to expensive molds, and the need for skilled labor, resulting in increased costs and installation complexities.
Innovation Solution
The use of polyurethane reaction injection molding with support ribs and a contoured drain wall design to ensure uniform cooling and integration of modular components like curbs and benches, allowing for faster production and flexible design options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding processes are used to manufacture shower modules, then production can proceed with standard methods, but uneven cooling occurs leading to bowing and deformation
Solution Approach 1:
The patent introduces cooling channels as intermediary structures within the mold that circulate coolant to achieve uniform heat distribution. These channels act as a mediator between the hot polymer material and the cooling system, enabling controlled and even cooling throughout the shower module, thereby preventing bowing and deformation while maintaining manufacturing precision.
2Adaptability or versatility
If custom molds are created for different design options, then design flexibility increases, but manufacturing costs increase due to expensive mold creation
Solution Approach 1:
The patent segments the shower module into standardized components (base, walls, bench, curb) that can be produced using common molds. By dividing the overall design into modular segments, different combinations can be assembled to create various design options without requiring custom molds for each variation, thus maintaining design flexibility while controlling manufacturing costs.
Solution Approach 2:
The patent designs universal molds that can produce multiple component types through reconfiguration or by creating base components that serve multiple functions. For example, a single mold can produce shower bases that accommodate different wall configurations, or benches that can be installed in various positions, enabling one mold to serve multiple design purposes and reducing the need for expensive custom tooling.
3Adaptability or versatility
If manual construction methods are used for shower enclosures, then design customization is possible, but installation time and labor skill requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete shower module units in the factory including pre-installed benches, curbs, and wall panels. These pre-configured modules are delivered ready-to-install, eliminating the need for on-site construction and significantly reducing installation time while maintaining design customization through selection of different pre-configured module combinations.
Solution Approach 2:
The patent merges multiple separate construction elements (base, walls, bench, curb, drainage) into integrated prefabricated modules. By combining these components into single assembled units during manufacturing, the installation process is simplified to merely placing and connecting pre-built modules, dramatically increasing productivity while preserving design flexibility through modular selection.
4Manufacturing precision
If thick mortar layers are applied to create sloped shower floors, then proper drainage slope can be achieved, but curing time increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the sloped floor surface during the molding process itself. The shower module is manufactured with the correct drainage slope already built-in through the mold design, eliminating the need for subsequent mortar application and curing. This transfers the sloping operation to the manufacturing stage where it occurs instantly without time delay.
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 manufacturing time, minimizes waste, and provides a more uniform and leak-proof shower module system with increased design flexibility, improving installation efficiency and reducing costs.
Implementation Method 1
the shower module is cooled in the mold
Implementation Method 2
the polymeric material is injected into the mold and cooled to solidify the shower module
Implementation Method 3
the polymeric material is injected into the mold
Data Source
AI summary
A prefabricated shower bench for installation in a tiled shower includes an upper surface having a plurality of peripheral edges, and at least three sidewalls. Each sidewall has an upper edge and a lower edge. Each upper edge is connected along a corresponding peripheral edge of the upper surface. The lower edge of each sidewall terminates in a common plane. One sidewall includes a setback area along the entire lower edge which has a height greater than the height of a sidewall of a prefabricated shower module. The upper surface is horizontal or pitched downwards toward the shower module when the shower bench is installed adjacent to the sidewall of the shower module such that the sidewall of the shower module resides within the setback area, thereby preventing the weight of the shower bench from resting on the sidewall of the shower module.