Composite article
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Solution Overview
Problem
Existing shower trays require high amounts of resin for strength and durability, leading to environmental issues 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 enhanced strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high amounts of resin are used to provide strength and durability, then the shower tray achieves required mechanical properties, but the weight increases and environmental impact worsens
Solution Approach 1:
The patent uses a composite material system consisting of a skin layer (ABS capped acrylic or similar) combined with a resin-bonded filler matrix. This composite structure provides the necessary strength and durability while reducing overall weight compared to traditional solid resin construction. The skin provides structural integrity and the filler matrix provides support with lower density.
Solution Approach 2:
The patent applies different material properties to different parts of the shower tray. The skin layer receives a gel coat finish for a smooth, clean appearance and chemical resistance, while the filler matrix uses lightweight aggregates for weight reduction. This localized differentiation allows each component to perform its specific function optimally without requiring high resin content throughout the entire structure.
2Strength
If high amounts of resin are used to provide strength and durability, then the shower tray achieves required mechanical properties, but VOC emissions increase and environmental harm worsens
Solution Approach 1:
By using a composite structure with a skin layer and filler matrix, the patent reduces the total volume of resin required compared to traditional solid resin shower trays. This reduction directly decreases VOC emissions during manufacturing and installation while maintaining structural integrity through the synergistic combination of materials.
Solution Approach 2:
The patent changes the resin content parameter from traditional high levels (typically 30-50% by weight) to reduced levels (10-20% by weight in the filler matrix). This parameter change significantly reduces VOC emissions while the composite structure and gel coat finish compensate to maintain the required strength and durability.
3Strength
If high amounts of resin are used to provide strength and durability, then the shower tray achieves required mechanical properties, but the manufacturing cost and transport energy increase
Solution Approach 1:
The composite construction with lightweight filler materials reduces the overall weight of the shower tray, directly decreasing transport energy requirements. The skin layer provides structural strength while the filler matrix provides bulk support with lower density, achieving the required mechanical properties with reduced mass.
4Ease of manufacture
If traditional gel coat finish is used, then the shower tray can be manufactured, but the finish quality is poor and walls break easily
Solution Approach 1:
The patent applies a gel coat finish specifically to the skin layer that will be visible and in contact with water, providing a smooth, clean, and chemically resistant surface. The walls are reinforced with additional layers or mesh to prevent breaking. This localized application of gel coat to the appropriate substrate resolves the issue of poor finish quality and wall fragility while maintaining ease of manufacture.
Data Source
AI summary
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.