Solid Foam Core Bathroom Fixture Design to Reduce Deflection and Cost

The patent applies composite materials by combining a hollow acrylic/ABS/fiberglass exterior shell with an inner foam core and polymer reinforcement layer. This composite structure achieves superior deflection resistance compared to solid materials of the same weight, resolving the contradiction between strength and manufacturing cost. The foam core (typically polyurethane or polystyrene) provides rigid support while the polymer reinforcement layer (epoxy or polyester resin with glass fibers) bonds the core to the shell, creating a lightweight yet highly rigid composite fixture that costs less than traditional solid materials.

The patent applies local quality by concentrating reinforcement materials only where needed rather than uniformly throughout the entire fixture. The polymer reinforcement layer is applied specifically at the interface between the hollow shell and foam core, and the foam core itself is positioned to provide support where deflection is most likely to occur. This localized approach to reinforcement reduces material costs while achieving the required deflection resistance.

The patent employs composite materials to achieve deflection resistance comparable to cast iron while dramatically reducing weight. The combination of hollow shell, foam core, and polymer reinforcement layer creates a lightweight structure that is easier to handle and install than traditional cast iron fixtures, while the composite construction provides the necessary rigidity to eliminate deflection issues.

The patent applies the nesting principle by placing the foam core inside the hollow exterior shell, creating a nested structure where the core provides internal support. This nested configuration achieves high rigidity and deflection resistance without the weight of solid cast iron, as the foam core and reinforcement layer work together to stiffen the hollow shell structure.