Seamless Vinyl Floor Drain Integrating Finishing Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing floor drain systems face issues with watertight sealing, wear-resistance, and bacterial growth due to the use of non-walkable sealing membranes and clamping rings, which are difficult to maintain and lead to undesirable bacterial growth, especially in hospital environments.
Innovation Solution
A floor part with a seamless, flexible finishing layer that bounds the inflow opening of the drain, eliminating the need for clamping rings and ensuring a reliable, antibacterial surface by integrating the finishing layer with the drain during manufacturing, using materials like PVC and ABS, and methods like ultrasonic welding or multi-shot moulding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing membrane is used to achieve watertight sealing, then watertightness is improved, but wear-resistance deteriorates and the surface becomes non-walkable
Solution Approach 1:
The patent merges the sealing membrane layer and the walkable finishing layer into a single integrated vinyl sheet layer. This layer simultaneously provides watertight sealing functionality and sufficient mechanical strength for walking, eliminating the need for separate layers and resolving the contradiction between watertightness and wear-resistance.
Solution Approach 2:
The vinyl sheet layer serves multiple functions: it acts as a watertight sealing membrane, provides a walkable surface with adequate wear-resistance, and offers a smooth cleaning surface. This multi-functional design resolves the contradiction by making a single layer capable of both sealing and bearing foot traffic.
2Ease of manufacture
If a sealing membrane with rough web layer is used to ensure adhesion, then adhesive bonding is improved, but ease of cleaning deteriorates due to dirt and bacteria accumulation
Solution Approach 1:
The patent changes the surface parameter of the vinyl sheet layer from rough (like sealing membrane web layers) to smooth. This parameter change maintains adequate adhesion through the vinyl material properties and adhesive systems while dramatically improving ease of cleaning by eliminating the rough texture where dirt and bacteria accumulate.
3Reliability
If clamping rings are used to secure the flexible layer, then connection reliability is improved, but device complexity increases and bacterial growth areas are created
Solution Approach 1:
The patent extracts and removes the clamping ring component from the drain assembly. Instead of using a separate clamping mechanism, the vinyl sheet layer is directly integrated with the drain body through molding or adhesive bonding. This eliminates the additional component, reduces structural complexity, and removes the crevices where bacteria could accumulate.
Solution Approach 2:
The patent merges the function of the clamping ring into the integrated vinyl sheet layer and drain body assembly. The securing function that previously required a separate mechanical component is now achieved through the integrated design, simplifying the overall structure while maintaining connection reliability.
4Reliability
If transitions from flexible layer to clamping ring are created, then secure connection is achieved, but harmful factors increase due to dirt accumulation and bacterial growth
Solution Approach 1:
The patent removes the transition zone between the flexible layer and clamping ring by eliminating the clamping ring component entirely. The vinyl sheet layer flows continuously from the walkable surface into the drain tray, creating a seamless design with no crevices or transitions where dirt and bacteria could accumulate.
Solution Approach 2:
Instead of creating a transition from the flexible layer to a rigid clamping ring, the patent inverts the approach by having the flexible vinyl sheet layer continuously integrate with the drain tray. This reverses the traditional design logic and eliminates the harmful transition zone that caused bacterial growth problems.
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
The solution provides a reliable, antibacterial, and easy-to-clean floor surface with reduced bacterial growth risks, simplifying maintenance and renovation by eliminating transitions and ensuring a seamless, walkable surface.
Implementation Method 1
the edge of the flexible finishing layer is heated and pressed onto the drain
Implementation Method 2
the edge of the flexible finishing layer is heated and pressed onto the drain
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The disclosure relates to a floor part, comprising a walkable floor part surface and a drain arranged in the floor part, which drain has a bottom surface and walls rising from the bottom surface, which standing walls connect to the walkable floor part surface, wherein at least the whole floor part surface is formed by a seamless, flexible finishing layer such as a vinyl layer, and wherein the inflow opening of the drain is bounded by the seamless, flexible finishing layer.