Method for preparing a reinforced structure
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Solution Overview
Problem
Existing methods for manufacturing sanitary structures like bathtubs and shower trays using synthetic resins face issues such as heavy weight, brittleness, high maintenance costs, and failure to meet thermal shock resistance standards due to excessive mineral filler addition, and they often use potentially carcinogenic styrene-based resins.
Innovation Solution
A process involving shaping a thermoplastic or thermosetting resin into a receptacle, mixing thermosetting polymer precursors at room temperature to form a liquid formulation with specific viscosity and density, adding a filler with controlled humidity and density, and polymerizing it to create a reinforced structure that is self-smoothing and resistant to thermal shocks without using styrene-based resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If mineral filler is added to reduce resin cost, then product cost decreases, but weight increases and brittleness increases
Solution Approach 1:
The patent changes the particle size parameter of the filler from conventional fine particles to coarse particles (0.5-5mm), and controls humidity parameter (<0.1%), which fundamentally alters how the filler integrates with the polyurethane resin. This parameter change allows achieving cost reduction with minimal impact on weight and mechanical properties, as coarse particles create fewer stress concentration points compared to fine particles.
Solution Approach 2:
The patent creates a composite material system combining polyurethane resin with specific coarse mineral fillers (marble, silica, or calcium carbonate) under controlled humidity conditions. This composite approach optimizes the synergistic effect between resin and filler, achieving cost efficiency while maintaining structural integrity and resistance to thermal shock, avoiding the brittleness issue associated with conventional filler additions.
2Quantity of substance
If mineral filler is added to reduce resin cost, then product cost decreases, but mechanical strength decreases
Solution Approach 1:
The patent changes the particle size parameter to coarse range (0.5-5mm) and controls humidity parameter (<0.1%), which fundamentally alters the stress distribution in the composite material. Coarse particles reduce stress concentration effects compared to fine particles, thereby maintaining mechanical strength even at high filler loadings (30-70% by weight).
Solution Approach 2:
The patent develops a specialized composite material using polyurethane resin combined with coarse mineral fillers under strict humidity control. This composite structure optimizes the interface between resin and filler, ensuring effective stress transfer and maintaining high mechanical strength and thermal shock resistance despite high filler content.
3Weight of moving object
If synthetic resin is used instead of traditional materials, then weight decreases and installation becomes easier, but thermal shock resistance becomes insufficient
Solution Approach 1:
The patent creates a composite material system combining polyurethane resin with coarse mineral fillers (marble, silica, or calcium carbonate) where the filler serves dual functions: maintaining the lightweight advantage of synthetic resins while providing thermal stability. The controlled humidity condition (<0.1%) ensures optimal bonding between resin and filler, creating a composite that resists thermal shock through the thermal mass and stability of the mineral particles.
Solution Approach 2:
The patent changes the filler particle size to coarse range (0.5-5mm) and controls humidity parameter (<0.1%), which creates a composite structure with improved thermal shock resistance. The coarse particles create a more open structure that allows thermal stress distribution, while the low humidity ensures complete polymerization and strong interfacial bonding, both critical for thermal shock resistance.
4Quantity of substance
If styrene-based resin is used instead of polyurethane, then cost decreases, but harmful VOC emissions increase
Solution Approach 1:
The patent replaces the harmful styrene-based resin with polyurethane resin that uses water or other non-VOC substances as the liquid component. This substitution eliminates the carcinogenic VOC emissions while maintaining the economic viability through optimized filler usage. The process converts a harmful chemical system into a safer alternative without sacrificing cost-effectiveness.
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 process results in a reinforced structure that is lighter, more durable, and resistant to thermal shocks, eliminating the need for additional machinery and reducing material waste, while ensuring compliance with thermal shock resistance standards.
Implementation Method 1
polymerization of said thermosetting formulation with said filler, thus forming a reinforced structure
Data Source
AI summary
The present invention relates to the use of composite reinforcements advantageously comprising a thermosetting matrix and a filler in the reinforcement of thermoplastic material or thermosetting resin, in order to obtain a structure such as a bathtub, a basin, a wall panel or a shower tray. reinforced shower. The present invention relates more particularly to a process for preparing a reinforced structure using composite reinforcements, as well as the structure capable of being obtained by such a process.