Modular Polymeric Spa Framing System

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Solution Overview

Problem

Existing modular construction systems for swim spas and hot tubs are limited by the need for large prefabricated elements and specialized tooling, which restricts flexibility and adaptability to varying dimensions and configurations.

Innovation Solution

A modular construction system utilizing keyed vertical and horizontal framing members combined with corner connectors, allowing for the creation of lightweight, polymeric, and infinitely configurable frames without the need for large prefabricated elements or specialized tooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If large prefabricated elements and specialized tooling are used, then structural strength and stability are improved, but flexibility and adaptability to varying dimensions are worsened

Engineering Contradiction:

Improvestructural strengthVSAvoidflexibility to varying dimensions

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The framing system is divided into discrete modular components including vertical members, horizontal members, and corner connectors that can be independently manufactured and assembled. This segmentation enables the structure to be configured in various dimensions and shapes while maintaining structural integrity through standardized connection mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner connectors and framing members are designed with universal connection features that allow the same components to be used across different spa configurations and dimensions. The standardized interface enables a single set of parts to serve multiple functions in different assembly configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If large prefabricated elements are used, then structural stability is improved, but ease of manufacture and material cost are worsened

Engineering Contradiction:

Improvestructural stabilityVSAvoidease of manufacture

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

By breaking down the structure into smaller standardized components, each piece can be manufactured using conventional molding techniques rather than requiring specialized tooling for large prefabricated elements. This reduces manufacturing complexity and cost while maintaining overall structural stability through modular assembly.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If specialized tooling is required, then manufacturing precision is improved, but device complexity and cost are worsened

Engineering Contradiction:

Improvemanufacturing precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system uses standardized dimensional parameters and connection geometries that can be achieved through conventional manufacturing processes rather than specialized tooling. By establishing consistent scaling relationships between components, high manufacturing precision is attainable through standard equipment while avoiding the complexity of specialized molds and fixtures.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If modular components are used, then adaptability to different dimensions is improved, but connection complexity may increase

Engineering Contradiction:

Improveadaptability to dimensionsVSAvoidconnection complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The corner connectors integrate multiple connection functions into a single unified component that joins vertical and horizontal members simultaneously. This merging of connection features simplifies the overall assembly process and reduces the number of separate fastening operations required compared to separate connection mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The framing members incorporate self-aligning and self-securing connection features that automatically position and secure components during assembly without requiring complex alignment procedures or specialized fastening operations. The interlocking geometry provides inherent positioning and structural integrity.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250073121A1Modular framing system for spas, hot tubs, and other large water containment vessels

Publication Date: 2025.03.06 MAY MFG

AI summary

A modular frame and system for supporting a swim spa, hot tub, or other water containment vessel is contemplated. The system includes a plurality of keyed vertical members attachable to cooperating grooves in horizontal rails. The ends of the horizontal rails attach via keyed projections to a corner bracket, while a retaining member secures to a groove in horizontal rail to secure an integrated protective bottom sheet. All of these components can be manufactured in standardized dimensions relying upon low-cost, light-weight polymeric materials. Methods and systems for using these components in a variety of customizable arrangements are also contemplated.