Prefabricated Shower Bench Setback Structure for Fast Tiled Installation
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Solution Overview
Problem
Existing prefabricated shower modules face issues with uneven cooling during manufacturing, leading to bowing and warping, which affects the pitch and integrity of the shower surface, and limits design options due to the need for specific molds and integrated features like drains and curbs, making them costly and difficult to install.
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 customizable shower modules with improved installation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If prefabricated shower modules are manufactured using injection molding with integrated drains and curbs, then installation time is reduced, but manufacturing cost increases due to the need for specific molds
Solution Approach 1:
The shower module is divided into separate components: the base module without integrated drains or curbs, and separate drain and curb modules that can be attached later. This segmentation allows the base module to be manufactured using a single generic mold, reducing manufacturing cost, while still providing the benefit of prefabrication for reduced installation time.
Solution Approach 2:
A single generic mold is designed to produce base modules that can accommodate multiple drain types and curb configurations. This universal base module design eliminates the need for separate specialized molds for each drain/curb combination, reducing manufacturing cost while maintaining the prefabricated installation advantage.
2Productivity
If the shower module is removed from the mold before complete solidification, then manufacturing productivity increases, but the module experiences bowing and warping
Solution Approach 1:
The ejection process is segmented into two stages: first, the base module is partially ejected from the mold while still slightly pliable, and second, the module completes its solidification after removal. This allows faster cycle times without permanent deformation, as the module can be gently manipulated during the transition period before fully hardening.
Solution Approach 2:
The mold design incorporates preliminary ejection features that begin the removal process while the material is still in a semi-pliable state, allowing the module to be gently guided out before complete solidification. This preliminary action reduces the required cooling time while preventing bowing through controlled, gentle ejection rather than forced removal.
3Adaptability or versatility
If conventional construction methods are used to create shower enclosures, then design flexibility is maintained, but installation time and skill requirements increase
Solution Approach 1:
The system segments the shower enclosure into modular components (base module, drain module, curb module, sidewall modules) that can be independently manufactured and then assembled. This segmentation maintains design flexibility through various combination options while dramatically reducing installation time compared to conventional monolithic construction methods.
Solution Approach 2:
The system provides dynamic adaptability where modules can be configured in different arrangements and heights to suit various design requirements. The adjustable curb heights and multiple drain position options allow the installation to adapt to different spatial constraints and design preferences without requiring custom manufacturing, thus maintaining flexibility while using prefabricated components.
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 and costs by minimizing warping and bowing, increases design flexibility, and enhances the leak-proof integrity of shower enclosures, enabling faster and more reliable installation of tiled shower systems.
Implementation Method 1
the module must cool (e.g., solidify) before being removed
Implementation Method 2
the module must cool (e.g., solidify) before being removed
Implementation Method 3
polyurethane reaction injection molding
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.