Resin Composite Sanitary Ware With Low-Energy Self-Cleaning Surface
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Solution Overview
Problem
Current sanitary ware manufacturing methods, particularly those using ceramics, are environmentally detrimental and resource-intensive, and alternative materials like acrylic and glass fiber reinforced plastic are costly and complex to produce with limited self-cleaning capabilities.
Innovation Solution
A resin-based composite sanitary ware is created by mixing unsaturated polyester resin, anti-shrinking medium, reinforcing fibers, scale stone, calcium carbonate, and initiator, then injecting and solidifying the mixture under high pressure in a thermosetting plastic injection machine, utilizing low-cost and abundant materials like scale stone and calcium carbonate, and employing a specific ratio of styrene to unsaturated polyester resin for improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramics are used to make sanitary wares, then the products have good strength and durability, but the production process consumes a lot of energy and requires rare earth mineral resources
Solution Approach 1:
The invention changes the material composition parameters by using resin-based composite materials (unsaturated polyester resin, calcium carbonate, scale stone, aluminum hydroxide) instead of traditional ceramics, eliminating the need for high-temperature kiln burning while achieving comparable mechanical properties through chemical bonding and filler reinforcement
Solution Approach 2:
The invention creates a composite material system combining organic resin matrix with inorganic fillers (calcium carbonate, scale stone, aluminum hydroxide) to achieve both the strength requirements and reduced energy consumption, as the composite structure provides mechanical reinforcement without requiring sintering
2Ease of manufacture
If acrylic or glass fiber reinforced plastic is used to make sanitary wares, then the production process is simpler and energy consumption is reduced, but the cost is high and self-cleaning capacity is low
Solution Approach 1:
The invention applies local quality enhancement by incorporating aluminum hydroxide particles specifically to provide flame resistance and self-cleaning properties at the surface level, while maintaining the overall composite structure for manufacturing simplicity and cost-effectiveness
Solution Approach 2:
The invention modifies the compositional parameters by adding aluminum hydroxide (6-10% by weight) to the resin composite system, which enhances flame resistance and self-cleaning capacity without significantly affecting the ease of manufacture or increasing cost
3Ease of manufacture
If traditional resin composite methods are used, then the production cost is low, but the product strength and tenacity are insufficient
Solution Approach 1:
The invention creates a multi-component composite material system where unsaturated polyester resin provides the matrix, calcium carbonate and scale stone provide structural reinforcement, and aluminum hydroxide provides additional strength and functional properties, achieving high strength at low cost through synergistic material combinations
Solution Approach 2:
The invention enhances specific local properties by incorporating scale stone (10-20% by weight) which provides both mechanical reinforcement and surface hardness, while maintaining overall cost-effectiveness through the use of abundant, low-cost filler materials
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 reduces production costs and energy consumption, enhances product strength and tenacity, and results in a smooth, self-cleaning surface with high self-cleaning capacity, suitable for mass production with reduced labor and defect rates, while maintaining a lightweight and high-strength product.
Implementation Method 1
Unsaturated polyester resin composition 14%-30%; Initiator 0.8%-2.4%
Implementation Method 2
the unsaturated polyester anti-shrinking medium is made by diluting unsaturated polyester resin with a thermoplastic polymer
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 mold; and the ingredients of the raw materials and their weight ratios are as follows: unsaturated polyester resin composition 14%-30%; unsaturated 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.