Composite Toilet Support Frame Reducing Weight and Corrosion
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Solution Overview
Problem
Existing support structures for wall-hung toilets, typically made of metal, face issues with weight, cost, assembly time, and corrosion, while requiring significant mechanical strength due to the stresses they endure.
Innovation Solution
A support structure made from a composite material comprising a plastic matrix filled with reinforcing fibers, which reduces weight and cost, eliminates corrosion, and enhances mechanical strength through geometry and the integration of encapsulation elements for electronic devices, allowing for a more efficient assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal frame is used for the support structure, then mechanical strength is sufficient, but weight is excessive and cost is high
Solution Approach 1:
The patent applies composite materials consisting of a plastic matrix reinforced with fibers (such as glass, carbon, or organic fibers) to replace traditional metal frames. This composite structure provides sufficient mechanical strength while significantly reducing weight and cost, directly resolving the contradiction between strength and weight.
2Strength
If a metal frame is used for the support structure, then mechanical strength is sufficient, but assembly time is excessive
Solution Approach 1:
The patent merges multiple separate metal components (uprights, crossbar, support pieces) into a single integrated composite structure. This monolithic design eliminates the need for assembly operations such as welding or bolting, thereby reducing assembly time while maintaining structural integrity through the inherent strength of the composite material.
3Strength
If a metal frame is used for the support structure, then mechanical strength is sufficient, but corrosion resistance is poor
Solution Approach 1:
The patent uses composite materials with a plastic matrix and fiber reinforcement that inherently resist corrosion. Unlike metal frames that are susceptible to rust and degradation in humid environments, the composite material provides durable corrosion resistance while maintaining the necessary mechanical strength for supporting the toilet structure.
4Weight of stationary object
If the support structure is made from composite material, then weight is reduced and cost is reduced, but mechanical strength may be insufficient
Solution Approach 1:
The patent carefully selects and formulates composite materials with appropriate fiber types (glass, carbon, organic), fiber content (30-70% by weight), and matrix materials (polypropylene, polyethylene, polyester, vinyl ester) to achieve the required mechanical strength. The composite structure is designed to provide sufficient load-bearing capacity while maintaining weight reduction benefits.
Solution Approach 2:
The patent implements local reinforcement strategies by varying fiber distribution and concentration in different regions of the composite structure. High-stress areas receive enhanced fiber reinforcement while low-stress areas use lighter formulations, optimizing mechanical strength where needed while maintaining overall weight reduction.
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 material support structure is lighter, less expensive, and faster to assemble, providing sufficient mechanical strength and corrosion resistance, while integrating electronic components for improved management of suspended toilet equipment.
Implementation Method 1
The support piece, the cross member, and at least the lower portion of the uprights are made in one piece from a composite material comprising a matrix of plastic material loaded with reinforcing fibers
Data Source
Figure 1~2
Figure 3~4
Figure 5~8
AI summary
The support structure (10) comprises two uprights (11) and a crossmember (12) which connects the two uprights and in which the upper part of the bowl (1) is fastened. Each upright has an upper portion (15) that is situated above the crossmember and serves as a support for the tank (3), and a lower portion (14) that holds feet (17) for fastening to the ground. The support structure comprises a supporting part (30) which is situated under the crossmember and at a distance from the latter and which connects the two uprights. The supporting part serves to support the lower part of the bowl, under the drainage pipe (5). The supporting part (30), the crossmember (12) and at least the lower portion (14) of the uprights (11) are made in one piece of composite material comprising a matrix of plastics material loaded with reinforcing fibres.