Sanitary article

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Sanitary items made with composite materials containing hollow glass spheres often require reworking, which leads to superficial microporosity during mechanical processing, causing dirt accumulation and increased cleaning efforts due to the grinding of these spheres.

Innovation Solution

A sanitary object with a support body made of a composite material containing hollow glass spheres, coated with a thin outer layer of a polymeric binder matrix without hollow glass spheres, which seals the surface and prevents microporosity, allowing for smooth processing without the drawbacks of hollow glass spheres.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If hollow glass spheres are added as filler to reduce product weight and cost, then weight reduction and cost reduction are achieved, but mechanical reworking creates superficial microporosity leading to dirt accumulation

Engineering Contradiction:

Improveproduct weightVSAvoiddirt accumulation

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The sanitary object is divided into two distinct parts: a support body made of composite material containing hollow glass spheres for weight reduction, and an outer coating made of composite material without hollow glass spheres to provide a non-porous surface that prevents dirt accumulation. This segmentation allows each part to fulfill its specific function without the drawbacks of the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The harmful component (hollow glass spheres) is extracted from the outer coating layer while being retained in the support body. The outer coating is made of a polymeric binder matrix filled with alternative fillers but explicitly excludes hollow glass spheres, thereby eliminating the source of microporosity and dirt accumulation on the surface.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If hollow glass spheres are ground during mechanical post-processing, then surface smoothness is improved, but hollow glass spheres generate superficial microporosity

Engineering Contradiction:

Improvesurface smoothnessVSAvoidsurface porosity

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

Different regions of the sanitary object have different material compositions tailored to their specific requirements. The support body contains hollow glass spheres for weight reduction, while the outer coating uses alternative fillers to provide a dense, non-porous surface structure suitable for mechanical processing without generating microporosity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses composite materials with different compositions for different layers: the support body uses a composite with hollow glass spheres, while the outer coating uses a composite with alternative fillers (such as aluminum trihydrate, quartz, or other inorganic fillers) that do not create microporosity when ground, achieving both surface smoothness and compositional stability.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If outer coating is applied to seal the surface, then microporosity is prevented, but the coating thickness increases

Engineering Contradiction:

Improvemicroporosity preventionVSAvoidcoating thickness

Core Design Contradiction:

Object-affected harmful factorsVSLength of stationary object

Solution Approach 1:

The outer coating is applied as a thin layer that provides sufficient sealing to prevent microporosity and dirt accumulation without excessive thickness. The coating contains fillers that allow it to achieve the required protective function with minimal thickness, avoiding unnecessary increase in the overall dimensions of the sanitary object.

Inventive Principle:

Principle #16Partial or excessive action

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 solution provides a sanitary item with reduced weight and cost, maintaining excellent haptic and optical properties while ensuring a clean, non-porous surface that prevents dirt accumulation, as the outer coating is thin and does not require reworking, thus eliminating microporosity issues.

Implementation Method 1

an outer coating applied at least in sections to it and forming the outside of the sanitary object, the outer coating made of a second composite material consisting of a polymeric binder matrix filled with at least one filler and which does not contain any hollow glass spheres

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

a filled polymeric binder matrix containing at least one filler in the form of hollow glass spheres

Methodology Applied

Scientific EffectPolymer binding: Binder

Data Source

PatentEP3892599A1Sanitary article

Publication Date: 2021.10.13 DURAVIT AG

Figure 1~2
Figure 3~4

AI summary

Sanitary article comprising a supporting body (2) and an outer coating (3) applied at least partially to the supporting body forming the outer surface of the sanitary article, wherein the supporting body (2) consists of a first composite material (4) of a filled polymeric binder matrix (6) containing at least one filler in the form of hollow glass spheres (7) and the outer coating (3) of a second composite material (5) of a polymeric binder matrix (10) filled with at least one filler and which does not contain hollow glass spheres.