Dual-layer metal bathtub and basin construction method

Abstract

A dual-layer metal bathtub and basin and its construction method is disclosed. The tub has an inner layer 102 made of high chrome alloy or stainless steel and an outer layer 104 made of metals such as copper, brass. zinc, or tin. The inner layer and outer layer are bonded together at a bonding area 106. There is an ergonomic top edge 108 and a base 110 which combines the inner and outer layers. There is also a drainage outlet. The construction method includes bonding the inner and outer layer using welding or another appropriate bonding technique. The tub and basin are manufactured in a variety of sizes and shapes without using plating techniques.

Description

Background The field of the invention pertains to the construction of bathtubs and basins in the sanitary ware industry. Specifically it focuses on the innovative method of creating dual-layer metal structures utilizing various combinations of metals, shapes, and sizes to enhance durability functionality and aesthetic appeal. The invention presented here addresses a longstanding need in the field of sanitary ware, particularly in the manufacturing and design of bathtubs and basins. Historically, the industry has explored various materials and designs to enhance functionality, durability, and aesthetic appeal. Traditional materials like porcelain, acrylic, and enameled cast iron have been prevalent, but they come with limitations in terms of durability, wear resistance, and aesthetic versatility In recent years, there has been a trend towards using metals such as copper and stainless steel for their aesthetic appeal and durability While copper offers a beautiful patina and antimicrobial properties, it is susceptible to oxidation, resulting in discoloration and degradation over time. Stainless steel, known for its corrosion resistance and durability lacks the warm, luxurious appearance of copper. Two recent patents, WO2023116436A1 and WO2023116606A1, demonstrate ongoing efforts to innovate in bathtub design. WO2023116436A1 describes a bathtub with a unique structural design, featuring a hard pool body and a soft pool body made of materials like PVC. The design emphasizes a detachable connection system with elements such as fences, corner beams, and an intricate assembly of cover plates and transition pieces. While this modular approach allows for customization and adaptability in design, it does not address the material limitations of traditional bathtubs, such as oxidation and long-term durability WO2023116606A1 presents a bathtub liner concept utilizing a soft pool body (also PVC-based) designed to fit within a hard outer frame. The liner includes a water holding cavity and a connecting part, offering a solution for easy installation and maintenance. Although this design enhances flexibility and potential ease of cleaning, it does not significantly advance the material properties of the bathtub itself, particularly regarding oxidation resistance and long-term durability. Comparison and Advancement: The present invention significantly advances the state of the art by introducing a dual-layer construction combining high chrome alloy (stainless steel) with other metals such as copper, brass, zinc, or tin. Unlike the patents mentioned above, which focus on structural design and modularity, this invention concentrates on material innovation. The bonding of stainless steel with another metal, without resorting to plating, presents a novel approach to address the issues of oxidation, durability, and aesthetic appeal. By using stainless steel internally, the invention effectively prevents the oxidation issues prevalent in copper bathtubs while maintaining the desired aesthetic qualities. This dual-layer metal approach represents a substantial improvement over existing technologies in terms of longevity, maintenance, and overall performance of sanitary wares. Statement of invention The present invention introduces a groundbreaking approach in the field of sanitary ware, particularly in the design and construction of bathtubs and basins. The core innovation lies in the development of a dual-layer metal combination, integrating high chrome alloy (typically stainless steel) with other metals such as copper, brass, zinc, or tin. This invention marks a significant departure from traditional single-material designs and offers numerous advantages in terms of functionality, durability, and aesthetic appeal. Key Features of the Invention: Dual-Layer Construction: The invention employs a dual-layer structure where high chrome alloy is bonded with a second metal, providing robustness and durability. Material Choices: High chrome alloy offers inherent advantages such as corrosion resistance and scratch resistance, while the second metal layer adds aesthetic and functional value. Oxidation Resistance: Incorporating stainless steel prevents oxidation issues, ensuring long-lasting appearance and performance. Enhanced Durability: The dual-layer construction enhances product longevity by resisting erosion and acid reaction. Versatility in Design: The invention allows for various shapes and sizes to cater to different preferences and bathroom layouts. Non-Plated Approach: Unlike existing designs, this invention does not rely on plating techniques, ensuring durable and long-lasting construction. Targeted Application: Primarily for the sanitary ware sector, specifically for bathtubs and basins requiring both aesthetic appeal and high functionality. In summary, this invention represents a significant advancement in the field of sanitary ware by introducing a novel dual-layer metal combination for bathtubs and basins, offering enhanced durability, oxidation resistance, and design versatility. This innovation addresses the limitations of current materials and designs, setting a new standard in the industry. Advantages Enhanced Durability: The incorporation of a dual-layer construction, combining high chrome alloy (stainless steel) with metals such as copper, brass, zinc, or tin, results in a bathtub and basin with superior durability. This construction method ensures resistance to erosion, acid reaction, and other forms of wear and tear, prolonging the lifespan of the sanitary ware. Oxidation Resistance: By utilizing stainless steel as the inner layer of the bathtub and basin, the invention effectively prevents oxidation issues commonly associated with copper-based materials. This feature maintains the long-lasting appearance and performance of the sanitary ware, eliminating concerns about discoloration and degradation over time. Aesthetic Versatility: The dual-layer construction allows for the integration of various metals, offering versatility in design and aesthetic appeal. Whether it's the warm, luxurious appearance of copper or the sleek, modern look of stainless steel, the invention caters to diverse consumer preferences and bathroom styles, enhancing the ambiance of any space. Functional Innovation: The method innovatively addresses material limitations found in traditional bathtubs and basins, such as oxidation and long-term durability. By combining different metals in a dual-layer structure, the invention achieves a balance between functionality and aesthetic appeal, setting a new standard in the industry. Maintenance Ease: Unlike existing designs that may require frequent maintenance and care, the dual-layer metal construction method ensures easy upkeep and cleaning. The non-plated approach eliminates concerns about surface damage or degradation over time, offering a hassle-free solution for maintaining the sanitary ware’s appearance and performance. Customization Options: With the ability to incorporate various shapes, sizes, and surface finishes, the invention allows for customization to suit different user preferences and bathroom layouts. This flexibility in design ensures that the dual-layer metal bathtub and basin can seamlessly integrate into any residential or commercial space, enhancing both functionality and visual appeal. Industry-Leading Performance: The introduction of this innovative construction method represents a significant advancement in the field of sanitary ware. By addressing key challenges faced by traditional materials and designs, the invention sets a new standard for durability, functionality, and aesthetic versatility, positioning itself as a leader in the industry. Overall, the dual-layer metal bathtub and basin construction method offers a multitude of advantages over existing technologies, making it a compelling choice for consumers seeking high-quality, long-lasting sanitary ware solutions. Introduction to drawings To fully illustrate the innovative aspects of this dual-layer metal bathtub and basin invention, a series of detailed drawings are provided. These drawings serve to visually represent the design, construction, and unique features of the invention. Below is a description of each drawing: Figure 1 - Top perspective View of the Bathtub / Basin. Figure 2 - Side Perspective View of the Bathtub / Basin. Figure 3 - Top Perspective View of the Bathtub / Basin. Figure 4 - Side Perspective View of the Bathtub / Basin. Figure 5 - Side Perspective View of the Bathtub / Basin. Figure 6 - Side View of the Bathtub / Basin. Figure 7 - Front View of the Bathtub / Basin. These drawings collectively provide a comprehensive visual representation of the dual-layer metal bathtub and basin invention, highlighting its unique features, construction techniques, and the significant improvements it offers over existing sanitary ware products. Reference numerals in the drawings To facilitate a clear and detailed understanding of the drawings associated with the dual-layer metal bathtub and basin invention, reference numerals are assigned to specific components and areas within the drawings. Below is a list of these reference numerals along with their corresponding elements: 100. Dual-Layer Bathtub / Basin: Represents the overall structure of the bathtub or basin, consisting of the inner and outer layers bonded together. 102. Inner Layer (High Chrome Alloy / Stainless Steel): Denotes the inner layer of the bathtub or basin, typically made of high chrome alloy, particularly stainless steel, known for its durability and resistance to corrosion and scratches. 104. Outer Layer (Copper / Brass / Zinc / Tin): Represents the outer layer of the bathtub or basin, which can be crafted from various metals such as copper, brass, zinc, or tin, contributing to the product's aesthetic appeal and specific functional properties. 106. Bonding Area: indicates the junction where the high chrome alloy (inner layer) and the second metal (outer layer) are fused together. It highlights the method of bonding, whether through welding or another technique. 108. Top Edge of Bathtub / Basin: Refers to the upper boundary or rim of the bathtub or basin, often designed for ergonomic comfort and aesthetic finish. 110. Base of Bathtub / Basin: Represents the bottom part or base of the bathtub or basin, which may include design considerations for stability and water drainage. 112. Bonding Area of The Base: Indicates the junction where the second metal (outer layer) and the base of the bathtub / basin are fused together. It highlights the method of bonding employed in this area. 114. Drainage Outlet: Represents the position and design of the drainage outlet, an essential feature for the functionality of the bathtub or basin. These reference numerals are crucial for understanding the detailed aspects of the drawings and for grasping the innovative features and components of the dual-layer metal bathtub and basin invention. Detailed description The detailed description of the dual-layer metal bathtub and basin construction method is provided below, with reference to the accompanying drawings. In Figure 1, which illustrates the top perspective view of the bathtub / basin, several key components are identified. The inner layer (102), composed of high chrome alloy or stainless steel, forms the core structure of the bathtub / basin, providing durability and corrosion resistance. At the top edge of the bathtub / basin, indicated by reference numeral 108, ergonomic design considerations are incorporated for user comfort. Additionally, the drainage outlet, represented by reference numeral 114, ensures efficient water drainage, maintaining cleanliness and hygiene. Figure 2 provides a side perspective view of the bathtub / basin, highlighting its dual-layer construction. The inner layer (102), consisting of high chrome alloy or stainless steel, is surrounded by the outer layer (104), which can be made of metals such as copper, brass, zinc, or tin. The bonding area (106) between these layers ensures structural integrity, enhancing the longevity of the bathtub / basin. At the top edge (108) and base (110) of the bathtub / basin, design elements are incorporated for both aesthetic appeal and functional stability. The bonding area of the base (112) further reinforces the connection between the layers. Moving to Figure 3, which presents the top perspective view of the bathtub / basin, we observe the continuation of the dual-layer construction. The inner layer (102) and outer layer (104) are clearly depicted, along with the top edge (108) and base (110) of the bathtub / basin. The bonding area of the base (112) ensures a secure connection between the second metal layer and the base structure, contributing to overall stability and durability. Additionally, the drainage outlet (114) facilitates efficient water drainage, preventing stagnation and maintaining hygiene. Figure 4 offers a detailed side perspective view of the bathtub / basin, emphasizing the dual-layer construction and structural features. The inner layer (102) provides a robust core structure, white the outer layer (104) adds aesthetic appeal and specific functional properties. The bonding area (106) between these layers ensures a strong and durable connection, critical for withstanding the rigors of daily use. The top edge (108) and base (110) of the bathtub / basin are designed for both user comfort and stability, with additional reinforcement provided by the bonding area of the base (112). Continuing to Figure 5, we observe another side perspective view of the bathtub / basin, focusing on its structural integrity and design elements. The dual-layer construction, consisting of the inner layer (102) and outer layer (104), is evident, along with the bonding area (106) between these layers. The top edge (108) and base (110) of the bathtub / basin are designed to ensure both ergonomic comfort and stability, enhancing the overall user experience. Additionally, the bonding area of the base (112) reinforces the connection between the second metal layer and the base structure, enhancing durability. Figure 6 presents a side view of the bathtub / basin, highlighting specific design features and structural components. The outer layer (104), made of metals such as copper, brass, zinc, or tin, contributes to the aesthetic appeal of the bathtub / basin. The bonding area (106) ensures a secure connection between the inner and outer layers, providing structural stability. At the top edge (108) and base (110) of the bathtub / basin, design considerations are incorporated for both visual appeal and functional performance. The bonding area of the base (112) further reinforces the connection between the layers, enhancing overall durability. Finally, Figure 7 offers a front view of the bathtub / basin, providing a comprehensive overview of its design and structural features. The dual-layer construction, consisting of the inner layer (102) as shown in figure 1, and outer layer (104), is clearly depicted, along with the bonding area (106) between these layers. The top edge (108) and base (110) of the bathtub / basin are designed for ergonomic comfort and stability, enhancing the user experience. The bonding area of the base (112) further reinforces the connection between the second metal layer and the base structure, ensuring long-lasting durability. In summary, the detailed description and accompanying drawings elucidate the innovative aspects of the dual-layer metal bathtub and basin construction method. This method offers numerous advantages in terms of durability, functionality, and aesthetic appeal, making it a valuable contribution to the field of sanitary ware.

Claims

What is claimed is:

1. A dual-layer metal bathtub and basin comprising:an inner layer (102) made of high chrome alloy or stainless steel;an outer layer (104) made of metals such as copper, brass, zinc, or tin, wherein the inner layer and outer layer are bonded together at a bonding area (106) to form a robust and durable structure;a top edge (108) designed for ergonomic comfort and aesthetic finish;a base (110) that combines the inner layer and the outer layer to provide structural stability and support; anda., drainage outlet (114) strategically positioned to facilitate efficient water drainage, preventing stagnation and maintaining hygiene.

2. The dual-layer metal bathtub and basin of claim 1, wherein the high chrome alloy or stainless steel inner layer provides inherent advantages such as corrosion resistance and scratch resistance.

3. The dual-layer metal bathtub and basin of claim 1, wherein the outer layer made of metals such as copper, brass, zinc, or tin enhances the aesthetic appeal and specific functional properties of the bathtub and basin.

4. The dual-layer metal bathtub and basin of claim 1, wherein the drainage outlet is integrated into the design to efficiently remove water, maintaining cleanliness and hygiene in the bathtub and basin.

5. A dual-layer bathtub and basin construction method comprising:an inner layer (102) made of high chrome alloy or stainless steel; andan outer layer (104) made of copper, brass, zinc, or tin.

6. The construction method of claim 5, wherein the inner layer is bonded with the outer layer through welding or another appropriate bonding technique.

7. The construction method of claim 5, wherein the high chrome alloy provides corrosion resistance and scratch resistance to the bathtub or basin.

8. The construction method of claim 5, wherein the outer layer enhances the aesthetic appeal of the bathtub or basin.

9. The construction method of claim 5, wherein the dual-layer structure prevents oxidation issues commonly associated with copper bathtubs.

10. The construction method of claim 5, further comprising a bonding area (106) where the inner layer and outer layer are fused together.

11. A dual-layer metal bathtub and basin as claimed in claim 5, further comprising a base (110) that combines the inner layer and the outer layer to provide structural stability and support.

12. The dual-layer metal bathtub and basin of claim 5, wherein the drainage outlet (114) is integrated into the design to efficiently remove water, maintaining cleanliness and hygiene in the bathtub and basin.

13. The construction method of claim 5, wherein the bathtub or basin is manufactured in various shapes and sizes to accommodate different preferences and bathroom layouts.

14. The construction method of claim 5, wherein the bathtub or basin is designed without relying on plating techniques for enhanced durability.

15. The construction method of claim 5, wherein the bathtub or basin is primarily intended for use in the sanitary ware sector, combining aesthetic appeal with high functionality.

Images