Solid Surface Wet Room Floor for Corrosion and Fire Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pre-fabricated wet room floors face issues with corrosion, weight, fragility, and fire safety, particularly in marine and hotel applications, where they require frequent maintenance and fail to meet high temperature standards.
Innovation Solution
A pre-fabricated wet room floor made of a solid surface material composed of aluminum trihydrate (ATH) or aluminum monohydrate (AMH) with a polymer binding medium, providing a wear-resistant, lightweight, and corrosion-resistant surface that can withstand high temperatures up to 200°C, with a preferred ATH or AMH content of 50-90% by weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel construction with concrete and clinker is used, then structural strength and fall to drain is improved, but weight becomes very heavy
Solution Approach 1:
The patent applies composite materials by combining a light-weight core structure with a solid surface material layer. The core provides structural strength while the solid surface material (comprising ATH or AMH and polymer binding medium) provides the wear-resistant, non-corroding surface. This composite approach achieves the required structural integrity without the excessive weight of traditional steel-concrete-clinker constructions.
2Strength
If steel construction is used, then structural features and fall to drain are achieved, but corrosion and rust occur leading to regular maintenance
Solution Approach 1:
The patent replaces traditional steel construction with a composite material system consisting of a non-corroding core structure and a solid surface material layer. The solid surface material comprises ATH or AMH (aluminum trihydrate or aluminum monohydrate) and a polymer binding medium, creating a corrosion-resistant construction that eliminates the maintenance issues associated with painted steel while maintaining structural integrity and fall-to-drain features.
3Weight of stationary object
If glass-fibre reinforced plastic construction with gel-coat is used, then weight is reduced and corrosion is prevented, but fragility and fire safety issues arise
Solution Approach 1:
The patent changes the chemical composition parameters of the solid surface material by using ATH or AMH (which have high thermal stability and fire resistance) combined with a polymer binding medium. This composition achieves both light weight and improved fire safety compared to gel-coat solutions, while the solid surface material provides enhanced durability and reduced fragility. The material can withstand higher temperatures without melting or deforming.
Solution Approach 2:
The patent uses a composite material system where the solid surface material (ATH/AMH + polymer) is applied over a structural core. This composite construction provides the light weight advantage while simultaneously achieving the fire resistance and durability that pure glass-fibre gel-coat constructions lack. The solid surface material layer protects the underlying structure and provides the wear-resistant surface.
4Object-affected harmful factors
If gel-coat surface is used, then stain resistance is achieved, but temperature resistance is limited to 70°C causing fire hazards
Solution Approach 1:
The patent fundamentally changes the temperature resistance parameter by replacing gel-coat with solid surface material comprising ATH or AMH and polymer binding medium. ATH and AMH are aluminum compounds with high thermal stability that do not melt or deform at temperatures where gel-coat fails. This material composition enables the floor to withstand temperatures well above 70°C, eliminating fire hazards while maintaining stain resistance and chemical resistance properties.
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 results in a durable, low-maintenance floor that is easy to adapt in size and shape, resistant to stains and chemicals, and meets stringent fire safety standards, reducing maintenance costs and ensuring long-term durability.
Implementation Method 1
The wear surface, that is the upper surface of the floor subjected to wear from usage of the wet room floor, being made of said solid surface material, will produce a very wear-resistant surface, that is light weight and does not corrode. A minimum of maintenance will be needed having such a wet room floor. The pre-fabricated wet room floor preferably further has a solid surface material with a ATH or AMH content of 50 - 90% by weight, more preferably 60 - 80% by weight and most preferably 70-80% by weight. The high ratio of ATH or AMH to binder material will give the material good heat resistance. Tests has shown that by having 80% ATH or AMH to binder in the solid surface material, the material will withstand temperatures of up to 200°C
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a pre-fabricated wet room floor (1) comprising a wear surface (2, 2') that is made of a solid surface material, wherein said solid surface material is composed of aluminium trihydrate (ATH) or aluminium monohydrate (AMH) and a polymer binding medium, wherein said solid surface material has a ATH or AMH content of above 50%.