Method for bathing vessel having wood-containing base board
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Solution Overview
Problem
Existing bathing vessels made from plastic materials face challenges in meeting the minimum performance requirements set by standards like ANSI, particularly in terms of strength and deflection, which are not adequately addressed by current manufacturing methods.
Innovation Solution
A bathing vessel is manufactured using a wood-containing composite panel chemically bonded with a polyurethane material, featuring a multi-layer structure of acrylic, acrylonitrile butadiene styrene, and polyurethane materials, eliminating the need for separate adhesives and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic materials are used to manufacture bathing vessels, then the manufacturing process is simple, but the strength and deflection resistance do not meet ANSI standards
Solution Approach 1:
The patent uses composite materials consisting of wood-containing composite panels bonded with polyurethane material to create a bathing vessel base that meets ANSI strength requirements. This composite construction provides the necessary structural integrity while maintaining manufacturing feasibility through a multi-step process involving panel preparation, material application, and curing.
2Reliability
If separate adhesives are used to attach walls to the base, then the bonding process is simple, but the structural integrity is reduced
Solution Approach 1:
The patent merges the base construction and wall attachment processes by integrating the polyurethane material application directly onto the wood-containing composite panel. This eliminates the need for separate adhesive layers and creates a unified structural assembly, thereby improving structural integrity while managing complexity through process integration.
Solution Approach 2:
The multi-layer composite structure consisting of wood-containing panels, polyurethane material, and wall panels creates a unified composite construction that eliminates weak points associated with separate adhesive bonds. This composite approach ensures continuous structural integrity throughout the bathing vessel assembly.
3Strength
If wood-containing composite panels are used for the base, then the structural strength is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs preliminary action by preparing the wood-containing composite panels in advance with specific structural configurations before applying the polyurethane material. This pre-preparation of panels with appropriate dimensions and structural features simplifies the subsequent bonding process while ensuring the final assembly meets strength requirements.
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 method ensures compliance with ANSI standards by providing the necessary strength and deflection resistance, reducing the risk of structural weakness and the need for additional adhesives, while maintaining a durable and effective bathing vessel design.
Implementation Method 1
The polyurethane material is then cured while in contact with the wood-containing composite panel to chemically bond the polyurethane material with the panel
Data Source
AI summary
A method of manufacturing a bathing vessel includes forming a base by contacting an incompletely cured polyurethane material with a wood-containing composite panel. The polyurethane material is then cured while in contact with the wood-containing composite panel to chemically bond the polyurethane material with the panel. At least one wall is then attached to extend vertically from the base. The wall is a multi-layer structure of layers of acrylic material, acrylonitrile butadiene styrene material and the polyurethane material.