Prefabricated Sanitary Cell Kit With One-Piece Sheet Metal Base
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sanitary cell kits face challenges in simplifying prefabrication and assembly on construction sites, with complex assembly processes and materials that are not cost-effective or easy to manufacture and install.
Innovation Solution
A kit featuring a one-piece, folded, and welded sheet metal floor element with a supporting edge and prefabricated substructures made from profile rods, allowing for efficient and adaptable assembly, along with a hollow or open bottom for increased strength, and an integrated drainage system with an odor trap, enabling secure sealing and easy attachment of wall coverings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional materials and assembly methods are used for sanitary cell kits, then structural strength and stability can be achieved, but the prefabrication process becomes complex and assembly on construction site becomes difficult
Solution Approach 1:
The floor element integrates multiple components into a single prefabricated unit: the floor plate, drainage channel, odor trap pot, and supporting edge are all combined in one piece. This merging simplifies manufacturing and assembly while maintaining structural integrity through the integrated design.
Solution Approach 2:
The floor element is segmented into functional zones: a floor plate forming the walking surface, a drainage channel for water flow, an odor trap pot for sanitation, and a supporting edge for structural support. This segmentation allows each zone to be optimized independently while being manufactured as one piece.
2Strength
If heavy materials are used to ensure stability and strength of the floor element, then structural reliability improves, but transportation and handling become more difficult
Solution Approach 1:
The floor element uses composite construction with a metal framework providing structural strength and support, combined with a floor plate that can be made from various materials. This composite approach achieves high strength-to-weight ratio, ensuring stability while facilitating easier transportation and handling.
3Productivity
If the floor element is made as a complete one-piece structure, then manufacturing efficiency and sealing capability improve, but adaptability to different configurations becomes limited
Solution Approach 1:
The one-piece floor element incorporates locally optimized features: the floor plate area is designed for walking surface requirements, the drainage channel is positioned and shaped for water flow, the odor trap pot is located for sanitation function, and the supporting edge is configured for structural support. This local quality optimization allows the single piece to adapt to standard sanitary cell configurations while maintaining manufacturing efficiency.
4Adaptability or versatility
If traditional assembly methods with multiple components are used, then adaptability to different wall element configurations is improved, but assembly time and complexity on construction site increase
Solution Approach 1:
The floor element is preliminarily prepared as a complete, ready-to-install unit with all necessary components (drainage channel, odor trap pot, supporting edge) integrated during manufacturing. This preliminary action eliminates the need for on-site assembly of these components, significantly reducing construction time and complexity while maintaining adaptability through the standardized supporting edge design.
Data Source
Figure 1
Figure 2~3
AI summary
The assembly set (1) has a prefabricated structural element, a base element (2), wall elements (3-6) and a cover element (7). The base element is made up of molded sheet metal. The base element is formed as one-piece from a tilted sheet metal. The base element has a partially surrounding supporting edge and the wall elements have substructures (9,14,18) which are prefabricated from profile bars (10).