Spa Base Pan Ledge for Water Shedding and In-Ground Sealing
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Solution Overview
Problem
Current portable spas, hot tubs, and swim spas lack an effective design for shedding fluid away from the base pan when installed in-ground, leading to water pooling and risk of ground materials entering the unit, while also requiring additional external structures for protection and drainage.
Innovation Solution
A ground ledge design with an elevated inner edge that extends from the spa base pan, forming a ridge to shed water and protect against ground materials, while also serving as a base for external lights for safety and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base pan is kept flush with the facade structure, then manufacturing and aesthetics are improved, but protection from ground installation materials and fluid shedding capability deteriorates
Solution Approach 1:
The base pan is segmented into multiple functional zones: a flush facade portion for aesthetics, an extended ledge portion for protection, and a ridge portion for fluid shedding. This segmentation allows each zone to perform its specific function optimally without compromising manufacturing simplicity.
Solution Approach 2:
The base pan extends outward from the facade structure in the horizontal dimension, creating a ledge that projects beyond the facade. This dimensional extension provides the necessary protection from ground materials while maintaining a clean facade appearance.
2Reliability
If the base pan is extended outward to protect from ground materials, then protection capability is improved, but manufacturing complexity and aesthetic clean lines deteriorate
Solution Approach 1:
The extended ledge serves multiple functions simultaneously: it acts as a protective barrier from ground materials, provides a mounting surface for exterior lights, and creates a drainage plane for fluid shedding. This multi-functionality reduces the need for additional separate components.
Solution Approach 2:
The protection ledge, lighting mounting surface, and drainage features are merged into a single integrated base pan structure. This consolidation simplifies manufacturing compared to using separate protective structures, light mounts, and drainage systems.
3Reliability
If the base pan is extended outward to shed fluid, then fluid shedding capability is improved, but the structure becomes more complex and harder to manufacture
Solution Approach 1:
The ledge incorporates a curved ridge line that slopes downward from the facade outward to the ledge edge. This curved geometry naturally guides fluid flow away from the base pan while maintaining a smooth, continuous surface that is easy to mold and manufacture.
Solution Approach 2:
The base pan has different surface qualities in different zones: a smooth flush surface at the facade for aesthetics, a sloped shedding surface on the ledge for fluid drainage, and an extended projection for protection. Each local area is optimized for its specific function.
4Reliability
If additional external structures are added for protection and drainage, then protection and drainage capability are improved, but device complexity and installation complexity increase
Solution Approach 1:
The extended ledge integrates multiple protective and drainage functions into a single structure. It provides physical protection from ground materials, creates a drainage plane for fluid shedding, and offers a mounting surface for exterior lights, eliminating the need for separate protective structures, drainage systems, and light mounts.
Solution Approach 2:
The base pan combines the protective barrier function, drainage function, and lighting mounting function into one integrated component. This merging reduces the total number of parts, simplifies installation, and lowers overall system complexity compared to using separate structures for each function.
Data Source
AI summary
A uniquely shaped ledge that is incorporated around the top edge of the base pan on the bottom of a portable spa, hot tub or swim spa to seal and shed water while deflecting ground installation materials. The ledge is shaped in a manner that sheds liquids overflowing from the spa and water as rain from the outdoor environment while extending outward to prevent surrounding installation materials from overcoming the base pan when the spa is installed inground. The ledge is uniquely shaped and sized to adequately shed fluids and protect the spa from in-ground installation materials while allowing the innermost elevated rim, to fit up behind the spa facade structure forming an adequate water seal. In addition the ledge features dimensions suitable to provide an installation area for lights that illuminate the spa exterior for safety and a pleasing aesthetic. The characteristics of this ledge are disclosed herein.