Resin Composite Sanitary Ware for Low-Energy High-Strength Molding
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Solution Overview
Problem
Current sanitary ware manufacturing methods, particularly those using ceramics and complex resin-based materials, face environmental concerns, high costs, and limitations in self-cleaning capacity and material availability.
Innovation Solution
A resin-based composite sanitary ware is produced by mixing unsaturated polyester resin, polyester anti-shrinking medium, reinforcing fibers, scale stone, calcium carbonate, and initiator, then injected and solidified under high pressure in a thermosetting plastic injection machine, utilizing low-cost and abundant materials like scale stone and calcium carbonate, with specific weight ratios and additives for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramics are used to make sanitary ware, then the product has good strength and durability, but the manufacturing process consumes a lot of energy and rare earth mineral resources
Solution Approach 1:
The patent changes the material composition parameters by using resin-based composite materials (unsaturated polyester resin, calcium carbonate, aluminum hydroxide, etc.) instead of traditional ceramics, eliminating the need for high-temperature kiln burning while achieving comparable mechanical properties through chemical composition optimization
Solution Approach 2:
The patent substitutes expensive and scarce rare earth mineral resources with abundant and low-cost materials such as calcium carbonate and aluminum hydroxide, reducing both material cost and resource consumption while maintaining product performance
2Ease of manufacture
If resin and agate powder mixture is poured into the shell, then the product has general ceramic characteristics, but the process is complicated with high cost and low self-cleaning capacity
Solution Approach 1:
The patent uses a composite material system comprising unsaturated polyester resin, calcium carbonate, aluminum hydroxide, and other additives that collectively provide both manufacturing ease through injection molding and improved self-cleaning properties through the specific chemical composition and surface characteristics of the composite material
Solution Approach 2:
The aluminum hydroxide and calcium carbonate components in the composite material provide inherent self-cleaning properties through their chemical composition and surface characteristics, eliminating the need for additional complex surface treatment processes
3Quantity of substance
If scale stone and calcium carbonate are used as main raw materials, then the cost is reduced and energy consumption is saved, but the product must achieve high tenacity and strong strength
Solution Approach 1:
The patent creates a composite material system where unsaturated polyester resin serves as the binding matrix and calcium carbonate and aluminum hydroxide provide structural support and strength, achieving high mechanical properties through the synergistic combination of materials rather than relying on a single component
Solution Approach 2:
The patent optimizes the weight ratios of components (unsaturated polyester resin 14%-30%, calcium carbonate 25%-40%, aluminum hydroxide 6%-10%, Reinforcing fiber 11%-37%) to achieve the desired balance between cost reduction and mechanical strength enhancement
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 method results in a cost-effective, energy-efficient, and environmentally friendly product with high tenacity, strong strength, smooth surface, and high self-cleaning capacity, suitable for mass production with reduced labor and defects, and improved flame resistance and waterproofing.
Implementation Method 1
Unsaturated polyester resin 14%∼30%; Styrene 60%∼65%; and the weight ratio between the styrene and the unsaturated resin shall be as follows: Styrene 60%∼65%; Unsaturated resin 35%∼40%
Implementation Method 2
Inject the composites into the mould which will be heated to a temperature of between 130°C and 150°C, and maintain the pressure for the solidification
Data Source
AI summary
The invention discloses a resin-based composite sanitary ware, which is characterized in that: the sanitary ware is made by mixing up and injecting the raw materials and then solidifying the mould; and the ingredients of the raw materials and their weight ratios are as follows: unsaturated polyester resin 14%~30%; polyester anti-shrinking medium 6%~14%; reinforcing fiber 11%~37%; scale stone 10%~20%; calcium carbonate 25%~40%; initiator 0.8%~2.4%. And this invention also discloses the preparation method of the sanitary ware. Compared with the current technology, the invention has the advantages of strong strength, high tenacity, perfect self-cleaning capacity and low energy consumption.