Spa Shell Foam-Core Reinforcement to Replace Fiberglass

Solution Overview

Problem

Existing spa shell reinforcement methods, such as using fiberglass, are environmentally detrimental and may not provide sufficient strength to support spa shells under heavy loads, especially in larger spas like swim spas.

Innovation Solution

A shell reinforcing system comprising a structural support layer on the underside of the spa shell, consisting of an inner layer of rigidizer, a central foam layer, and an outer layer of rigidizer, which extends from the bottom side to the lip of the spa shell, forming ribs for additional support without using fiberglass.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fiberglass is used to reinforce the spa shell, then the structural strength is improved, but environmental harm increases due to volatile organic compound emissions and installation difficulties

Engineering Contradiction:

Improvestructural strengthVSAvoidenvironmental harm

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameters by substituting fiberglass with foam core material that has different physical and chemical properties. The foam material provides comparable structural strength while eliminating volatile organic compound emissions during installation, thus resolving the contradiction between strength and environmental harm.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material system consisting of a foam core layer sandwiched between inner and outer rigidizer layers. This composite structure achieves the required structural strength through the synergistic combination of materials, while the foam core specifically addresses the environmental harm issue by replacing fiberglass with a material that does not emit volatile organic compounds.

Inventive Principle:

Principle #40Composite materials

2Strength

If fiberglass is used to reinforce the spa shell, then the structural strength is improved, but installation complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidinstallation ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent changes the material parameters by substituting fiberglass with foam core material that has different physical and chemical properties. The foam material provides comparable structural strength while eliminating volatile organic compound emissions during installation, thus resolving the contradiction between strength and environmental harm.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material system consisting of a foam core layer sandwiched between inner and outer rigidizer layers. This composite structure achieves the required structural strength through the synergistic combination of materials, while the foam core specifically addresses the environmental harm issue by replacing fiberglass with a material that does not emit volatile organic compounds.

Inventive Principle:

Principle #40Composite materials

3Strength

If the structural support layer covers jet areas, then structural strength is improved, but jet installation becomes difficult

Engineering Contradiction:

Improvestructural strengthVSAvoidjet installation ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies the local quality principle by creating a jet opening template that defines specific uncovered areas where jets will be installed. The structural support layer is applied locally - covering areas needing reinforcement while deliberately leaving jet installation areas exposed. This allows the structural support layer to provide strength where needed without interfering with jet installation or functionality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the structural support layer application into covered areas and uncovered areas. The jet opening template creates distinct zones: covered zones for structural reinforcement and uncovered zones for jet installation. This segmentation allows simultaneous achievement of structural strength and ease of jet installation.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12329715B2Spa shell reinforcement systems and methods

Publication Date: 2025.06.17 BULLFROG INT L C

AI summary

A reinforcing system for a vessel that can contain water. The system includes a shell for containing water, the shell having one or more jets extending therethrough from an inside of the shell to an outside of the shell, and a structural support layer on an underside of the shell. The structural support layer can include: an inner layer of rigidizer applied to the underside of the shell, a central low density core, and an outer layer of rigidizer applied to the central low-density core. The structural support layer can extend from a bottom side of the underside of the shell, across at least one sidewall of the underside of the shell, and form at least one rib along the sidewall of the underside of the shell.