Polyurethane Bath Drain Structure for Load-Bearing Strength
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Solution Overview
Problem
The manufacturing process of resinous composite-shaped bathing vessels is labor-intensive due to the need to remove voids and air pockets from the glass-filled thermoset polyester supporting layer, and existing drain structures may not meet strength requirements for supporting user loads.
Innovation Solution
A bathing vessel design featuring a sandwich construction with a rigid polyurethane material and capping layers, including a blended area with specific curve geometries and material combinations to absorb loads and enhance strength around the drain, allowing for thinner construction while meeting strength requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a roller is used to remove voids and air pockets from the glass-filled thermoset polyester supporting layer, then the gel top coat layer is protected from puncture and damage, but the manufacturing process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent applies preliminary action by incorporating a release mat between the supporting layer and the gel top coat layer during the spraying process. This release mat is applied before the gel top coat is deposited, and it serves to absorb excess resin and trap voids/air pockets during the laying-up process. The release mat is then removed after curing, having already performed its function of protecting the gel top coat from defects, thus eliminating the need for subsequent roller operations to remove voids.
2Strength
If the polyurethane backing thickness is increased to meet strength requirements around the drain, then the drain can support user loads, but the overall vessel weight and material usage increase
Solution Approach 1:
The patent applies local quality by creating a blended area with enhanced polyurethane backing specifically around the drain location, while maintaining thinner polyurethane layers in other areas of the vessel. The blended area is formed by extending the side wall curvature downward to blend into the bottom, creating a localized zone of increased thickness and strength. This allows the drain to meet strength requirements for supporting user loads without increasing the overall weight of the entire vessel.
3Strength
If the polyurethane backing thickness is increased to meet strength requirements around the drain, then the drain can support user loads, but the material cost and manufacturing complexity increase
Solution Approach 1:
The patent applies spheroidality (curvature) by designing the blended area with continuous curved transitions. The side wall curvature is extended downward to blend into the bottom, creating smooth, continuous surfaces without sharp angles or discontinuities. This curved geometry not only provides the necessary structural strength around the drain but also simplifies the manufacturing process by allowing the polyurethane foam to be molded in one piece without requiring complex assembly or additional reinforcement components.
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 design improves manufacturing efficiency by reducing labor-intensive void removal and enhances drain strength to support user loads, meeting ANSI standards with a thinner, more rigid yet flexible structure.
Implementation Method 1
The side wall, the bottom wall, and the blended area flex to absorb loads adjacent the drain
Data Source
AI summary
A bathing vessel has a bottom, and a drain disposed in the bottom adjacent a blended area that is disposed between the side wall and the bottom. The side wall, the bottom wall, and the blended area are made of a first layer of rigid polyurethane material and a second layer of capping material attached to said first layer. A ratio of a density of the polyurethane backing adjacent the drain to a thickness of polyurethane backing is between 1-80:1. The side wall, the blended area and the bottom wall flex to absorb loads adjacent the drain.