Molded Resin Surface with Embedded Ferrous Particles
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Solution Overview
Problem
The high cost and limited availability of natural and engineered stone surfaces for bathroom and kitchen applications, along with the need for expensive equipment and sealing processes, create a demand for affordable alternatives with desirable aesthetics.
Innovation Solution
The development of molded solid surfaces incorporating ferrous particles, where a magnetic field is used to create predetermined patterns or docking locations within the resinous material, offering a cost-effective and aesthetically pleasing solution by embedding ferrous particles in resinous materials like acrylic or polyester, allowing for the creation of patterns and securing accessories magnetically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If natural and engineered stone surfaces are used for bathroom and kitchen applications, then desirable aesthetics and durability are achieved, but high cost and limited availability result
Solution Approach 1:
The patent combines ferrous particles with resinous materials to create a composite molded surface that mimics the appearance and durability of natural stone while significantly reducing material costs. The ferrous particles provide structural reinforcement and aesthetic appeal, while the resinous binder creates a durable, moldable composite material.
Solution Approach 2:
The patent alters the physical and chemical parameters of the resinous material through curing processes, transforming it from a liquid or semi-liquid state to a solid, durable surface. This parameter change enables the creation of stone-like surfaces with controlled properties such as hardness, flexibility, and aesthetic characteristics.
2Shape
If natural and engineered stone surfaces are used, then desirable aesthetics are achieved, but expensive equipment and sealing processes are required
Solution Approach 1:
The patent incorporates ferrous particles into the resinous material during the molding process itself, creating predetermined patterns and docking locations before the final product is formed. This preliminary action eliminates the need for subsequent sealing processes and complex equipment required by natural stone, as the aesthetic features are built-in during manufacturing.
Solution Approach 2:
The patent creates molded surfaces that copy the aesthetic appearance of natural stone through the strategic placement of ferrous particles within the resinous material. By using magnets to arrange particles in patterns that mimic natural veining or textures, the invention reproduces the visual appeal of expensive stone surfaces without requiring the same complex processing equipment.
3Manufacturing precision
If ferrous particles are embedded in resinous materials using magnetic fields, then patterns and docking locations are created, but additional manufacturing steps are introduced
Solution Approach 1:
The patent replaces traditional mechanical methods of pattern creation (such as manual placement or mechanical pressing) with magnetic field application. Magnets are used to attract and position ferrous particles within the resinous material, creating precise patterns and docking locations without requiring complex mechanical tooling or multiple manufacturing steps.
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
This approach provides a cost-effective alternative to natural stone surfaces with desirable aesthetics, reducing production costs and eliminating the need for expensive equipment, while enabling the creation of patterns and secure accessory mounting through magnetic forces.
Implementation Method 1
a magnetic field is used to create predetermined patterns or docking locations within the resinous material
Implementation Method 2
embedding ferrous particles in resinous materials like acrylic or polyester, allowing for the creation of patterns and securing accessories magnetically
Data Source
AI summary
The following embodiments include magnetic based devices, systems, and techniques applicable in a bathroom setting or a kitchen setting. A magnetic cleaning system is configured to clean a surface in the bathroom setting or kitchen setting. A magnetic mounting assembly is configured to mount a magnetic accessory. A cabinet includes the magnetic mounting assembly. A shower panel may include one or more magnetic acoustic shower tiles. A levitating drain stopper system for a basin is configured to magnetic open or close an opening in the basin. A magnetic water steering device is configured to magnetically direct water in a predetermined path.