Flush-mounted control panels for bathing installations
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Solution Overview
Problem
Conventional control panels in bathing installations, such as spas and whirlpool baths, protrude above the surface due to their thickness, making them susceptible to damage and affecting their aesthetic appearance.
Innovation Solution
A flush-mounted control panel system is implemented using a peripheral support bracket with adhesive seals, where the panel is fitted into a recessed opening in the tub, minimizing protrusion and ensuring secure attachment without the need for cutting a large opening, utilizing a stainless steel or plastic bracket with overlapping lips and waterproof adhesive gaskets for support and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control panel is mounted using a conventional panel mounting flange secured by adhesive or mechanical fasteners, then the panel can be securely attached to the tub surface, but the panel protrudes above the surface due to the flange thickness, exposing it to damage and affecting aesthetic appearance
Solution Approach 1:
A support bracket is introduced as an intermediary component between the control panel and the tub surface. The bracket includes a first portion that receives the panel mounting flange and a second portion that extends into the tub to engage with the tub structure, thereby securing the panel without requiring the flange to protrude above the surface.
Solution Approach 2:
The mounting solution transitions from a two-dimensional surface mounting (flange on top surface) to a three-dimensional engagement (bracket extending into the tub). By utilizing the vertical dimension and engaging the tub structure from below, the panel can be securely mounted while maintaining a flush appearance at the surface level.
2Strength
If the panel mounting flange has appreciable thickness to provide structural support, then the panel can be securely mounted, but it protrudes above the tub surface, affecting aesthetic appearance and exposing the panel to damage
Solution Approach 1:
The support bracket acts as a mediator that distributes and transfers the structural load. Instead of the thick flange directly supporting the panel above the surface, the bracket transfers the load to the tub structure below, reducing the need for a thick protruding flange and thereby protecting the panel from damage.
Solution Approach 2:
The panel mounting flange is nested within the support bracket structure. The bracket's first portion receives the flange, effectively hiding the structural mounting components within the bracket assembly and presenting a flush surface to the exterior, thus protecting the panel while maintaining structural integrity.
3Ease of manufacture
If a large opening is cut in the tub surface to mount the control panel, then the panel can be installed, but it compromises the structural integrity and aesthetic appearance of the tub
Solution Approach 1:
The mounting system is segmented into multiple components: the control panel, the panel mounting flange, the support bracket with two distinct portions, and adhesive seals. This segmentation allows the bracket to engage the tub structure at a distance from the panel opening, requiring a smaller opening that preserves tub integrity while still enabling panel installation.
Solution Approach 2:
The support bracket serves as an intermediary that decouples the panel opening size from the structural engagement requirements. The bracket engages the tub structure below the surface, allowing the opening above the surface to be minimized for aesthetic and structural reasons, while the bracket provides the necessary structural connection.
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 provides a secure, aesthetically pleasing, and water-tight control panel installation that protects the panel from damage while maintaining a sleek appearance by ensuring the panel does not protrude above the tub surface, enhancing both functionality and visual appeal.
Implementation Method 1
a first waterproof adhesive gasket positioned at a second interface between the first lip structure and the tub surface
Data Source
AI summary
A flush-mounted control panel system for a bathing installation. The panel system includes a control panel including a housing structure, the housing structure including a peripheral mounting flange, the panel and flange sized to fit within a tub mounting opening in a mounting surface. A support bracket supports the control panel within the opening, and is fabricated of a thin material. The bracket has a peripheral sidewall portion, a top lip portion extending outwardly from the sidewall portion, and a bottom lip portion extending inwardly from the sidewall portion. The top lip portion overlays a portion of the surface peripheral to the opening and the bottom lip portion underlays the peripheral flange of the panel housing to support the panel within the opening. Adhesive gaskets secure the bracket to the mounting surface and the panel flange to the bottom lip portion.