Recycled Rubber Shower Base Composition for Insulation and Impact Resistance
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Solution Overview
Problem
Conventional shower bases made from resins lack insulating, elastic, and low-density properties, leading to noise transmission, thermal conductivity issues, and susceptibility to breakage, while also having a high environmental impact due to heavy materials.
Innovation Solution
Incorporating flexible fillings obtained from recycled car tires into the manufacturing process of shower bases, using a mixture of resin-based binding materials, minerals, and ground tire fillings, which improves physical properties like acoustic and thermal insulation, impact resistance, and reduces density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional resin materials are used for shower bases, then manufacturing simplicity and structural rigidity are maintained, but acoustic insulation, thermal insulation, and impact resistance are poor
Solution Approach 1:
The patent applies composite materials by combining recycled tire rubber particles with resin matrices to create a new material system. This composite structure integrates the elasticity and impact resistance of rubber with the structural properties of resin, achieving both improved mechanical performance and acoustic/thermal insulation while maintaining manufacturing feasibility
Solution Approach 2:
The patent changes the physical and chemical parameters of the material composition by incorporating recycled tire rubber particles of specific size ranges (0.5-5mm) into the resin system. This parameter modification transforms the material properties to achieve enhanced impact resistance, acoustic insulation, and thermal insulation without compromising structural integrity
2Strength
If heavy mineral fillers are used to provide strength, then structural strength is improved, but density and mass increase
Solution Approach 1:
The patent applies discarding and recovering by utilizing recycled tire rubber from end-of-life vehicles as a functional filler material. This recovered material replaces traditional heavy mineral fillers, providing structural reinforcement and impact resistance while significantly reducing the overall density and mass of the shower base
Solution Approach 2:
The patent employs recycled tire rubber particles as a cost-effective filler material that provides durable structural properties. The use of this recovered material eliminates the need for expensive heavy minerals while achieving comparable or superior mechanical performance with reduced weight
3Ease of manufacture
If traditional resin compositions are used, then manufacturing process simplicity is maintained, but environmental impact increases due to non-recyclable materials
Solution Approach 1:
The patent applies discarding and recovering by transforming waste tire rubber into a valuable construction material. The recycled rubber particles serve as functional fillers in the shower base manufacturing process, converting an environmental pollutant into a resource that reduces the need for virgin materials and minimizes waste disposal requirements
Solution Approach 2:
The patent applies self-service by creating a product that incorporates post-consumer waste materials into its structure. The recycled tire rubber not only fulfills a functional role as a filler and reinforcement agent but also demonstrates environmental responsibility, allowing the manufacturing process to contribute to waste reduction and sustainability goals
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 inclusion of recycled tire fillings reduces noise and thermal conductivity, enhances impact resistance and flexibility, decreases the shower base's mass by 25-30%, making manufacturing, handling, and installation easier while reducing environmental impact.
Implementation Method 1
A reduction in acoustic conductivity, thereby reducing the transmission of noise downstairs when the shower is used
Implementation Method 2
A reduction in thermal conductivity because the feeling of coldness in the feet is reduced when entering the shower
Implementation Method 3
An increase in resistance against impact, which thereby improves its behaviour in case of collision (the fall of objects or knocks while being handled, etc.)
Data Source
Figure 1~2
AI summary
An improved shower base due to the inclusion in its manufacture of flexible fillings from recycled car tyres, made using a mixture composed of resin-based agglomerant materials and fillings of different types of minerals to which flexible fillings are added made from ground or milled used tyres with a granulometry (of from 0.3 mm to 1.5 mm) and an optimum composition in percentage terms of each one of its components to attain a mixture that is as homogeneous as possible, thereby improving the physical and mechanical properties of the shower base while keeping the external appearance of a rigid mould intrinsic to conventional shower bases.