A composite article
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Solution Overview
Problem
Existing shower trays require high amounts of resin for strength and durability, leading to environmental pollution and heavy, difficult-to-install products.
Innovation Solution
A composite shower tray design using a skin with a resin bonded filler matrix containing up to 10% thermoset resin, combined with lightweight inorganic fillers and a metal mesh for improved strength and durability, and a resin bonded filler matrix, which includes a resin bonded filler matrix comprising a thermoset resin or precursor thereof in an amount of up to 10% by total weight of the resin bonded filler matrix, which includes a resin bonded filler matrix, which includes a resin bonded filler matrix, which includes a resin bonded filler matrix, which includes a resin bonded filler matrix comprising a thermoset resin or precursor thereof in an amount of up to 10% by total weight of the resin bonded filler matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high amounts of resin are used in the filler matrix, then strength and durability are improved, but environmental pollution increases and weight increases
Solution Approach 1:
The patent changes the chemical composition parameters of the resin system, using a specific ratio of polyol to isocyanate (2:1 to 5:1) and incorporating reactive diluents to reduce viscosity and VOC content. This allows achieving required strength with lower overall resin content while maintaining durability.
Solution Approach 2:
The patent creates a composite filler matrix system combining inorganic fillers (calcium carbonate, silica) with a modified polyurethane resin system. This composite approach provides structural strength through the filler framework while the resin acts as a binder, reducing the total resin content needed compared to traditional resin-heavy formulations.
2Strength
If high amounts of resin are used in the filler matrix, then strength and durability are improved, but weight increases making installation difficult
Solution Approach 1:
The patent modifies the resin system parameters by incorporating reactive diluents and adjusting the polyol-to-isocyanate ratio, which reduces the density and viscosity of the resin. This allows maintaining strength properties while reducing the weight contribution from the resin component.
Solution Approach 2:
The patent employs a composite structure where lightweight inorganic fillers (particularly calcium carbonate with specific particle size distributions) form the bulk of the filler matrix, providing structural strength with minimal weight. The resin content is reduced to essential binding requirements only, creating a high filler-to-resin ratio composite that optimizes the strength-to-weight ratio.
3Duration of action of stationary object
If high amounts of resin are used in the filler matrix, then durability is improved, but environmental pollution from VOCs increases
Solution Approach 1:
The patent changes the chemical parameters of the resin system by selecting specific polyol types (polyester or polyether) with controlled molecular weights and incorporating reactive diluents that reduce VOC emissions. The polyol-to-isocyanate ratio is optimized to ensure complete reaction and minimize unreacted volatile components, maintaining durability while reducing VOC content.
Solution Approach 2:
The patent applies different functional requirements to different components of the filler matrix. The inorganic fillers provide structural integrity and long-term durability, while the modified resin system provides binding and flexibility with minimal VOC emissions. This local specialization of functions allows durability to be achieved through the filler framework rather than relying on high resin content.
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 composite article achieves comparable strength and durability with reduced resin content, lowering environmental impact and weight, while maintaining improved physical properties.
Implementation Method 1
a polyurethane resin system formed from a polyol and an isocyanate
Data Source
Figure 1~3
Figure 4
AI summary
The present invention relates to a composite article for use as a shower tray comprising a skin and a resin bonded filler matrix, wherein the resin bonded filler matrix comprises a thermoset resin in an amount of up to 10 wt% by total weight of the resin bonded filler matrix.