Prefabricated Shower Bench Setback Structure for Watertight Tiled Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing prefabricated shower modules face issues with uneven cooling and warping due to non-uniform thickness, leading to bowed surfaces, compromised tile adhesion, and difficulties in achieving a watertight seal, which increases production costs and limits design options.
Innovation Solution
The use of polyurethane reaction injection molding with support ribs and a contoured drain wall design to ensure even cooling and uniform thickness, along with integrated modular curbs and shower benches, allows for faster production and increased design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding processes are used to produce shower modules, then production cost is reduced, but non-uniform thickness causes uneven cooling and warping
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional molding to polyurethane reaction injection molding, which fundamentally changes the material formation process. This enables precise control of material distribution and thickness uniformity during injection, directly resolving the warping issue caused by non-uniform cooling while maintaining cost-effectiveness through the efficiency of the injection molding process
2Stability of the object's composition
If module thickness is increased to prevent warping, then structural stability is improved, but production time increases due to slower cooling
Solution Approach 1:
The patent replaces conventional thermal cooling with chemical curing through polyurethane reaction injection molding. The polymeric material cures at controlled temperatures, eliminating the need for prolonged thermal cooling. This substitution of the curing mechanism allows the module to achieve structural stability without the time penalty associated with cooling thick sections in traditional molding processes
3Ease of manufacture
If non-uniform thickness is used to simplify manufacturing, then production complexity is reduced, but tile adhesion and watertight sealing are compromised
Solution Approach 1:
The patent changes the manufacturing parameter control from post-production correction to in-process control through reaction injection molding. The process enables precise control of material injection parameters to achieve uniform thickness directly during manufacturing, eliminating the need for complex post-processing while ensuring the high reliability needed for proper tile adhesion and watertight sealing
4Adaptability or versatility
If conventional shower modules are used, then basic functionality is provided, but design options are limited
Solution Approach 1:
The patent applies segmentation by dividing the shower system into separate modular components: shower modules, curbs, and benches. Each component can be independently manufactured using polyurethane reaction injection molding and then assembled to create various configurations. This segmentation enables design flexibility and adaptability while keeping individual module complexity manageable through standardized manufacturing processes
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 production time, minimizes waste, and enhances the quality of shower modules by preventing warping and ensuring a watertight seal, while offering more design options for customers.
Implementation Method 1
After filling the mold with the resin, the module must cool (e.g., solidify) before being removed
Implementation Method 2
If the module is removed before it is completely solid, bowing may occur as the module hardens. However, the mold or 'tool' for creating each unit can be quite expensive, thus a manufacturer generally limits the number of tools for producing each module. Therefore, the number of modules manufactured in a given amount of time depends on the amount of time required for one module to sufficiently cool enough to be removed from 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.