Interconnected Bathtub Shells for Leak-Safe Stackable Delivery
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Solution Overview
Problem
Existing bathtub manufacturing methods using thermoformed shells with fiberglass coatings face issues with volatile organic compound emissions, flammability, air and water leakages, and health hazards due to glass fibers, requiring costly and hazardous processes.
Innovation Solution
The use of two thermoformed plastic molded shells, where an outer shell with acrylic components and air jet forming through holes is bonded to an inner reinforcing support shell with channels, eliminating fiberglass and allowing for stackable and efficient storage and shipping, reducing transportation and storage costs, and enabling assembly only upon customer demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiberglass coating is used to reinforce thermoformed shells, then structural strength is improved, but volatile organic compound emissions and health hazards increase
Solution Approach 1:
The patent extracts and eliminates the fiberglass coating layer from the bathtub structure, replacing it with an integrated thermoformed plastic shell design that achieves structural strength without the harmful fiberglass material and its associated volatile organic compound emissions during manufacturing and disposal
Solution Approach 2:
The patent uses composite plastic materials with reinforcing fibers embedded during the thermoforming process itself, creating a structurally strong shell without requiring a separate fiberglass coating layer that emits harmful volatiles
2Strength
If glass fiber reinforced thermoplastic shell is used, then rigidity is improved, but flammability and smoke emissions increase
Solution Approach 1:
The patent changes the material composition parameters by using thermoplastic materials with inherent fire resistance properties and controlled flame spread ratings, replacing glass fiber reinforced thermoplastic with formulations that maintain rigidity while significantly reducing flammability and smoke emissions during combustion
3Strength
If fiberglass coating is applied to thermoformed shells, then structural reinforcement is achieved, but manufacturing complexity and quality control increase
Solution Approach 1:
The patent merges the structural reinforcement function directly into the thermoforming process itself, eliminating the separate fiberglass coating application step. The reinforcing structure is integrated into the shell formation process, reducing manufacturing complexity and eliminating quality issues associated with separate coating operations
Solution Approach 2:
The patent segments the bathtub into modular components (such as separate shell sections or pre-assembled units) that are manufactured independently and then joined, simplifying the manufacturing process for each component while maintaining overall structural reinforcement without requiring complex fiberglass coating operations
4Ease of operation
If complete bathtubs are shipped to customers, then delivery is convenient, but storage space and transportation costs increase
Solution Approach 1:
The patent divides the complete bathtub into separable components (such as shell sections, jets, and conduits) that can be shipped in a compact, nested arrangement where smaller parts fit within larger components, dramatically reducing storage space and transportation costs while allowing easy assembly at the destination
Solution Approach 2:
The patent implements a nested packaging system where smaller bathtub components are placed inside larger components during shipping and storage, creating a space-efficient configuration that minimizes volume requirements while maintaining ease of assembly when the components are unpacked and put together at the customer location
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
This method reduces environmental hazards, lowers production and transportation costs, and provides a healthier work environment by eliminating fiberglass, while ensuring the bathtub's rigidity and reducing storage space requirements.
Implementation Method 1
bonding means immovably secures the outer shell into the inner reinforcing support shell
Implementation Method 2
the channels forming conduits sealingly bonded about a plurality of air jet forming through holes
Data Source
AI summary
A hydromassaging bathtub is formed by molding an outer shell having an outer finished surface with an acrylic component therein and a plurality of air jets forming through holes, and an inner reinforcing support shell having channels molded in at least some of the inner side walls thereof. The inner shell has floor supports molded in a bottom wall thereof. The outer shell is bonded in the inner shell with the channels sealingly bonded about the plurality of air jet forming through holes. The method comprises stacking the similar shells together for shipping to an assembling and distribution site and for storage whereby to provide several commercial advantages in the manufacture and distribution of the bathtubs.