Spa Bulkhead Connector Assembly for Fewer Leak Points
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Solution Overview
Problem
The manufacturing and maintenance of spas with traditional jet systems are costly and time-consuming due to numerous potential leak points, and there is a need for efficient plumbing fixtures to connect modular jet packs to primary water and air supply lines.
Innovation Solution
The development of through bulkhead connectors with specific fitting members and grommets that provide a fluid-tight seal and easy connection between jet packs and supply manifolds, reducing the number of leak points and simplifying the installation and repair of spa systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional jet assemblies are used with individual water and air lines for each jet, then each jet can be independently controlled, but the number of potential leak points increases to 360 or more
Solution Approach 1:
The system is segmented into modular jet packs that can be independently replaced or serviced. Each jet pack contains multiple jets that share common water and air supply lines, creating independent functional modules that reduce system-wide leak risks while maintaining individual jet controllability through valve assemblies.
Solution Approach 2:
Multiple individual water and air lines are merged into single supply lines that serve entire jet packs. The bulkhead connectors combine multiple fluid pathways into unified connection points, reducing the total number of connection points and potential leak locations while maintaining the ability to control individual jets through integrated valve systems.
2Manufacturing precision
If individual jet assemblies with multiple fittings and connections are used, then each jet can be precisely positioned, but manufacturing time and cost increase significantly
Solution Approach 1:
Jet packs are pre-assembled with jets, fittings, and fluid lines configured in a standardized arrangement before installation in the spa. The bulkhead connectors are pre-configured with integrated sealing mechanisms and alignment features, allowing for rapid installation without requiring precise on-site positioning of multiple individual components.
Solution Approach 2:
The bulkhead connectors and jet packs are designed as universal, standardized components that can be used across different spa configurations. The standardized connection interfaces and modular design allow the same components to serve multiple functions and be installed in various positions, reducing manufacturing complexity and installation time while maintaining positioning accuracy.
3Ease of operation
If numerous individual fittings and connections are used for each jet, then fluid distribution to each jet is optimized, but repair and warranty costs increase due to high number of leak points
Solution Approach 1:
The fluid distribution system is segmented into modular jet packs where each pack contains a subset of jets sharing common supply lines. This segmentation allows for localized repair and replacement of only the affected jet pack rather than the entire system, reducing repair costs and downtime while maintaining efficient fluid distribution to all jets through the modular architecture.
Solution Approach 2:
The bulkhead connectors serve as intermediary components that provide integrated sealing and connection mechanisms between the spa shell and the jet pack supply lines. These connectors include built-in sealing elements and alignment features that simplify installation and repair procedures, reducing the skill level and time required for repairs while maintaining optimal fluid distribution.
4Reliability
If modular jet packs with single water and air supply connections are used, then the number of leak points is reduced, but specialized plumbing fixtures are required
Solution Approach 1:
The bulkhead connectors are designed as multi-functional components that simultaneously provide mechanical support, fluid sealing, and alignment functions. The standardized connection interfaces allow the same connector design to serve multiple jet packs and different spa configurations, reducing the need for highly specialized custom fixtures while maintaining reduced leak points through integrated sealing mechanisms.
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 bulkhead connectors enable quick and reliable fluid connections, reducing manufacturing and maintenance costs by minimizing leak points and allowing for easy upgrading and repair of spa systems, while ensuring a secure and efficient fluid flow.
Implementation Method 1
a grommet receivable on the body portion... such that the grommet forms a fluid-tight seal with the shell and such that the grommet forms a fluid-tight seal with the body portion
Implementation Method 2
the first passageway and the second passageway are in alignment with one another to allow for fluid flow through the first fitting member and the second fitting member
Data Source
AI summary
A through bulkhead connector for a spa includes a first fitting member and a second fitting member slidably connected to the first fitting member. The first fitting member includes a flange and an adapter portion extending from the flange and defining a passageway through the adapter portion and flange. The flange includes a receiving slot formed therein and which is open at one end for receiving a correspondingly shaped and dimensioned portion of the second fitting member.