Multi-Layer Composite Shower Tray for Lightweight Strength
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Solution Overview
Problem
Existing shower trays face issues with mechanical stability and weight, particularly acrylic trays being flexible and difficult to clean, and porcelain or mineral resin trays being heavy, which complicates installation and handling.
Innovation Solution
An ultra-light shower tray composed of multiple layers: a coating layer of unsaturated polyester resin, a combined glass fibre layer, a layer of extruded polystyrene pre-milled with slopes, and a mesh-reinforced extruded polystyrene sheet, providing enhanced mechanical stability and aesthetic homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acrylic resin with fibreglass reinforcement is used, then the tray feels flexible and has poor mechanical stability, but the material is difficult to clean and prone to damage
Solution Approach 1:
The patent applies composite materials by combining multiple layers with different properties: a structural layer for mechanical strength, a smooth top layer for ease of cleaning, and reinforcement layers. This resolves the contradiction by integrating materials that individually provide either strength or cleanability, but not both simultaneously.
Solution Approach 2:
The patent implements local quality by giving different layers different surface characteristics - the top layer is specifically designed to be smooth and non-porous for easy cleaning, while internal layers provide structural strength. This allows different regions of the tray to have optimized properties for their specific functions.
2Strength
If porcelain or mineral resin plates are used, then the tray has high mechanical stability, but the weight becomes very heavy
Solution Approach 1:
The patent uses composite materials combining lightweight polymers with fibreglass reinforcement and foam core, achieving high strength-to-weight ratio. This resolves the contradiction by replacing dense materials like porcelain with a multi-layer composite that provides equivalent structural performance at reduced weight.
Solution Approach 2:
The patent incorporates foam material in the core layer, which provides structural rigidity while maintaining low weight due to its porous structure. This allows the tray to achieve mechanical stability similar to solid materials but with significantly reduced weight.
3Weight of stationary object
If the tray is made ultra-lightweight, then the weight is reduced to approximately 12 kg/m2, but the mechanical stability must be maintained
Solution Approach 1:
The patent employs composite materials with fibreglass reinforcement and multi-layer construction that provides high strength-to-weight ratio, enabling ultra-lightweight design while maintaining mechanical stability.
Solution Approach 2:
The patent uses a multi-layered three-dimensional structure with varying thicknesses and material densities across different layers, optimizing the distribution of material to achieve lightweight construction without compromising structural integrity.
Data Source
Figure 1~2
Figure 3~4
AI summary
An ultra-lightweight shower tray made of a material composed of a coating layer based on an unsaturated polyester resin of isophthalic acid and neopentylglycol, a combined glass fibre layer of woven and non-woven glass fibres wetted with an unsaturated orthophthalic unsaturated polyester resin, a layer of extruded polystyrene; and a layer of mesh-reinforced extruded polystyrene sheet lining mortar.