Sanitary ware
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Solution Overview
Problem
Existing sanitary ware products, such as shower trays, are not fully recyclable and have resin-stone cores that are heavy, making them difficult to transport and install.
Innovation Solution
The use of a polymeric core, primarily composed of recyclable materials like polyethylene terephthalate (PET) or high-density polyethylene (HDPE), which can be lightweight and does not require strengthening ribs, combined with a polymeric outer layer, allowing for easier manufacturing and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin-stone core is used in sanitary ware, then the structural strength and stability are improved, but the weight of the product increases making it difficult to transport and install
Solution Approach 1:
The patent changes the material parameters by replacing resin-stone with polymeric materials for the core. This material substitution maintains structural strength while significantly reducing weight, allowing the product to meet strength requirements without the excessive weight of traditional resin-stone cores
Solution Approach 2:
The patent employs composite material construction with an outer layer and a core made of different polymeric materials. This composite structure allows optimization of each layer's properties - the outer layer provides surface durability while the polymeric core provides lightweight structural support, resolving the contradiction between strength and weight
2Stability of the object's composition
If a resin-stone core is used in sanitary ware, then the structural stability is improved, but the recyclability of the product is reduced
Solution Approach 1:
The patent changes the material composition parameters by using polymeric materials instead of resin-stone. These polymeric materials are selected to be recyclable, transforming the core from a non-recyclable material to one that can be recycled, thereby reducing environmental impact while maintaining structural stability
Solution Approach 2:
The patent enables the core material to be discarded and recovered through recycling processes. The polymeric core material can be recycled at the end of the product's life, allowing recovery and reuse of materials, which directly addresses the recyclability issue while maintaining structural performance
3Strength
If strengthening ribs are added to the core, then the loading capacity is improved, but the manufacturing complexity and material usage increase
Solution Approach 1:
The patent changes the material parameters of the core to use polymeric materials with inherent high strength-to-weight ratios. This material property change allows the core to achieve required loading capacity without adding complex strengthening ribs, thereby reducing manufacturing complexity and material usage while maintaining structural integrity
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a~2b
AI summary
An article of sanitary ware or part thereof, comprising an outer layer and a core. The outer layer comprises a first material and the core comprises a second material. The second material comprises one or more recyclable materials.