Patent Application
20250127342
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
The present disclosure relates generally to bathroom fixtures such as sinks, bathtubs, shower stalls, shower drain pans, shower or bath wall coverings, and the like. More particularly, the present disclosure pertains to solid core polymer reinforced bathroom fixtures.
Acrylic, Acrylonitrile Butadiene Styrene (ABS), and/or fiberglass are popular materials used to manufacture bathroom fixtures such as sinks, bathtubs, shower stalls, shower drain pans, shower or bath wall coverings, and the like. Acrylic, ABS, and/or fiberglass bathroom fixtures are durable, making them less prone to chipping or cracking compared to more brittle materials. Due to the non-porous nature, these fixtures generally resist staining and are relatively easy to clean. Acrylic, ABS, and/or fiberglass fixtures are generally hollow and lightweight, making them easier to handle and install compared to heavier materials. Finally, Acrylic, ABS, and/or fiberglass bathroom fixtures are affordable.
Acrylic, ABS, and/or fiberglass bathroom fixtures, while having many benefits, are prone to deflection, which refers to the bending or flexing of the material under pressure. This can occur if heavy objects are placed on the fixture or if someone leans or applies excessive force on a specific area. The material's deflection may be worsened due to the hollow design of many bathroom fixtures. Material deflection can lead to the development of cracks or structural damage over time.
Solutions to the deflection issue may include increasing the thickness of the material and including reinforcement materials such as glass fibers. These solutions, however, negatively impact the affordability of the products may increasing manufacturers production costs.
Alternative materials, such as cast iron still include hollow interior but do not have any deflection issues. This material type, however, is much more expensive and extremely heavy.
In view of at least some of the above-referenced problems in conventional Acrylic, ABS, and/or fiberglass bathroom fixtures implementations, an exemplary object of the present disclosure may be to provide an improved solid core reinforced bathroom fixture apparatus and method thereof is provided herein.
An exemplary such apparatus may include an exterior shell which includes a hollow inner portion similar to typical bathroom fixtures discussed above. An exemplary such apparatus may desirably feature an inner core (e.g., a molded foam block) configured to fill a majority of the hollow inner portion of the exterior shell. The exemplary such apparatus may feature a gap between the inner core and the exterior shell. The exemplary such apparatus may further feature a polymer reinforcement layer configured to adhere the inner core to the exterior shell, fill the gap, and fill any remaining hollow areas within the hollow inner portion of the exterior shell. The polymer reinforcement layer of the exemplary such apparatus may further include a hardener configured to reinforce the exterior shell when cured. The exemplary such apparatus may feature a drain reinforcement member positioned between the exterior shell and the inner core. The drain reinforcement member may strength the exterior shell proximate a drain opening and also seal the drain opening from the polymer reinforcement layer.
In a particular embodiment, an exemplary bath apparatus as disclosed herein may include an exterior shell, an inner core, and an adhesive coating defined between the exterior shell and the inner core. The exterior shell may include a protective outer surface and an inner surface defining a hollow inner portion. A central portion of the protective outer surface may generally be sloped towards a shell drain opening defined between the protective outer surface and the inner surface. The inner core may be positioned within the hollow inner portion of the exterior shell and may include at least one planar outer surface configured to be supported by an external support surface when the bath apparatus is installed.
In an exemplary aspect according to the above-referenced embodiment, the inner core includes a core drain opening aligned with the shell drain opening.
In another exemplary aspect according to the above-referenced embodiment, the bath apparatus may further comprise a drain reinforcement member including an upper flange, a reinforcement opening defined through the upper flange, and a downward extending rim surrounding the reinforcement opening and extending from the upper flange. The upper flange may be configured to engage the inner surface of the exterior shell surrounding the shell drain opening. The downward extending rim may be configured to be received by the core drain opening.
In another exemplary aspect according to the above-referenced embodiment, the inner surface of the exterior shell may include a downward protrusion surrounding the shell drain opening. The upper flange of the drain reinforcement member may include a channel surrounding the reinforcement opening. The channel may be shaped to receive the downward protrusion of the exterior shell.
In another exemplary aspect according to the above-referenced embodiment, the drain reinforcement member may further include a plurality of triangular reinforcements positioned between the upper flange and the downward extending rim.
In another exemplary aspect according to the above-referenced embodiment, the plurality of triangular reinforcements may be positioned between the downward extending rim and the reinforcement opening.
In another exemplary aspect according to the above-referenced embodiment, a diameter of the upper flange may be greater than twice that of the reinforcement opening.
In another exemplary aspect according to the above-referenced embodiment, a gap may be defined between the inner surface of the exterior shell and the inner core. The gap may include a plurality of gap distances defined perpendicular to the inner core.
In another exemplary aspect according to the above-referenced embodiment, the adhesive coating may be configured to fill the gap.
In another exemplary aspect according to the above-referenced embodiment, each of the plurality of gap distances may be less than or equal to a predetermined maximum gap distance.
In another exemplary aspect according to the above-referenced embodiment, the predetermined maximum gap distance may be less than or equal to 1 inch.
In another exemplary aspect according to the above-referenced embodiment, the gap may be greater than zero.
In another exemplary aspect according to the above-referenced embodiment, the gap decreases near one or more edges of the exterior shell. The one or more edges may be configured to engage the support surface when the bath apparatus is installed.
In another exemplary aspect according to the above-referenced embodiment, the gap may be substantially similar over a majority of the inner surface of the exterior shell.
In another exemplary aspect according to the above-referenced embodiment, the adhesive coating may form a continuous layer between the inner core and the inner surface of the exterior shell.
In another exemplary aspect according to the above-referenced embodiment, the adhesive coating may comprise polyurethane-based material.
In another exemplary aspect according to the above-referenced embodiment, the polyurethane-based material may include an expanding agent and hardener.
In another exemplary aspect according to the above-referenced embodiment, the exterior shell may have a consistent thickness of about 0.08 inch.
In another exemplary aspect according to the above-referenced embodiment, the exterior shell may have a thickness less than or equal to 0.1 inch.
In another exemplary aspect according to the above-referenced embodiment, the inner core may comprise a solid foam material. The solid foam material may have a density of between about 2.0 pounds per cubic foot and about 2.8 pounds per cubic foot.
In another exemplary aspect according to the above-referenced embodiment, a deflection of the bath apparatus relative to the exterior shell may be less than or equal to 0.05 inch.
In another embodiment, an exemplary method of assembling a bath apparatus as disclosed herein may include the steps of: (a) depositing an expanding adhesive material onto an inner surface of an exterior shell of the bath apparatus; (b) engaging a foam core of the bath apparatus with the expanding adhesive material to cause the expanding adhesive material to fill a gap defined between the foam core and the inner surface of the exterior shell; and (c) maintaining a position and pressure on the foam core relative to the exterior shell until the expanding adhesive material stops expanding and begins to cure.
Reference will now be made in detail to embodiments of the present disclosure, one or more drawings of which are set forth herein. Each drawing is provided by way of explanation of the present disclosure and is not a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the teachings of the present disclosure without departing from the scope of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment.
Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present disclosure are disclosed in, or are obvious from, the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.
The words “connected”, “attached”, “joined”, “mounted”, “fastened”, and the like should be interpreted to mean any manner of joining two objects including, but not limited to, the use of any fasteners such as screws, nuts and bolts, bolts, pin and clevis, and the like allowing for a stationary, translatable, or pivotable relationship; welding of any kind such as traditional MIG welding, TIG welding, friction welding, brazing, soldering, ultrasonic welding, torch welding, inductive welding, and the like; using any resin, glue, epoxy, and the like; being integrally formed as a single part together; any mechanical fit such as a friction fit, interference fit, slidable fit, rotatable fit, pivotable fit, and the like; any combination thereof; and the like.
Unless specifically stated otherwise, any part of the apparatus of the present disclosure may be made of any appropriate or suitable material including, but not limited to, metal, alloy, polymer, polymer mixture, wood, composite, or any combination thereof.
Referring to
The exterior shell 110 may define a protective outer surface 112 which is generally the surface that receives and interacts with water from a plumping fixture and/or a user of the bath apparatus 100. As illustrated in
The inner core 130 may be positioned within the hollow inner portion 120 of the exterior shell 110 and may be configured to help prevent deflection of the exterior shell 110. Additional details of the inner core 130 are illustrated in
As illustrated in
In certain optional embodiments, each of the plurality of gap distances 124 may be less than or equal to a predetermined maximum gap distance. The predetermined maximum gap distances may be less than or equal to 1 inch. In certain optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.9 inch. In other optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.8 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.7 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.6 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.5 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.4 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.3 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.2 inch. In further optional embodiments, the predetermined maximum gap distances may be less than or equal to 0.1 inch.
In certain optional embodiments, the inner surface 116 of the exterior shell 110 may include additional channels such as an upper channel 128 configured to define an upper rim 129 in the protective outer surface 112. In certain optional embodiments, the upper channel 128 may have a width less than or equal to the predetermined maximum gap distance. The gap distances associated with the upper channel 128 may be larger than the predetermined maximum gap distance. As such, a majority of the plurality of gap distances 124 may be less than or equal to the predetermined maximum gap distance. In other optional embodiments, over 60% of the plurality of gap distances 124 may be less than or equal to the predetermined maximum gap distance. In further optional embodiments, over 70% of the plurality of gap distances 124 may be less than or equal to the predetermined maximum gap distance. In additional optional embodiments, over 80% of the plurality of gap distances 124 may be less than or equal to the predetermined maximum gap distance. In still further optional embodiments, over 90% of the plurality of gap distances 124 may be less than or equal to the predetermined maximum gap distance.
In some optional embodiments, the gap 122 may be substantially similar over a majority of the inner surface 116 of the exterior shell 110. In other optional embodiments, the gap 122 may be consistent over 75% of the inner surface 116 of the exterior shell 110. In further optional embodiments, the gap 122 may be consistent over 80% of the inner surface 116 of the exterior shell 110. In certain optional embodiments, the gap 122 may be consistent over 85% of the inner surface 116 of the exterior shell 110. In other optional embodiments, the gap 122 may be consistent over 90% of the inner surface 116 of the exterior shell 110. In further optional embodiments, the gap 122 may be consistent over 95% of the inner surface 116 of the exterior shell 110.
In certain optional embodiments, the gap 122 may decrease as you approach the at least one rim 118 of the exterior shell 110. This may decrease a size of the opening between the inner core 130 and the exterior shell 110 for reducing the amount of adhesive coating which may escape when the inner core 130 is inserted into the hollow inner portion 120 of the exterior shell 110. This may further help to apply pressure to the adhesive coating 140 to thereby cause it to fill any other gaps, channels, or the like prior to escaping the opening between the inner core 130 and the exterior shell 110.
The adhesive coating 140 may be configured to couple the inner core 130 and the exterior shell 110, specifically the inner surface 116 of the exterior shell 110, together. The adhesive coating 140 may be configured to completely fill the gap 122. The adhesive coating 140 may form a continuous layer between the inner surface 116 of the exterior shell 110 or the inner core 130. In certain optional embodiments, the adhesive coating 140 may be sprayed, poured, or extruded (e.g., cylindrically like a bead) onto one of the inner surface 116 of the exterior shell 110 or the inner core 130. Ideally, the adhesive coating 140 is disposed on the inner surface 116 of the exterior shell 110 prior to insertion of the inner core 130 into the hollow inner portion 120 of the exterior shell 110.
The adhesive coating 140 may be a polyurethane-based material. The polyurethane-based material may be specifically formulated to expand once applied (e.g., include an expanding agent), for example, to fill in the gap 122. This expansion may be due to the presence of a blowing agent in the formulation, which reacts and releases gas bubbles as the adhesive cures. The expansion helps to fill gaps and voids between the bonded surfaces, improving adhesion strength and providing a more uniform bond line. The polyurethane-based material may further include a hardener in its formulation (e.g., a hardening agent), which results in the formation of cross-linked polymer chains as the material cures leading to the hardening and solidification of the adhesive coating 140. As such, the adhesive coating 140 is supported by the inner core 130, which may be supported by a support surface, and further supports the exterior shell 110.
As illustrated in
In certain optional embodiments, the inner surface 116 of the exterior shell 110 may include a downward extending portion 117 surrounding the shell drain opening 114. The downward extending portion 117 of the inner surface 116 may also be referred to herein as a downward extension 117 or a downward protrusion 117. The upper flange 152 of the drain reinforcement member 150 may further include a channel 158 surrounding the reinforcement opening 154. The channel 158 may be shaped to receive the downward extending portion 117 of the inner surface 116 of the exterior shell 110. In certain optional embodiments, each of the channel 158 and the downward extending portion 117 may be square shaped. In other optional embodiments, each of the channel 158 and the downward extending portion 117 may be circular, or some other shape. The interaction between the channel 158 and the downward extending portion 117 may prevent any of the adhesive coating 140 from seeping into the openings as it expands and cures. In certain optional embodiments, an adhesive or sealant may be applied between the upper flange 152 of the drain reinforcement member 150 and the inner surface 116 of the exterior shell 110.
The drain reinforcement member 150 may further include a plurality of triangular reinforcements 160 coupled between the upper flange 152 and the downward extending rim 156. In certain optional embodiments, the plurality of triangular reinforcements 160 may be positioned between the reinforcement opening 154 and the downward extending rim 156. As such, the plurality of triangular reinforcements 160 may be out of the way from interfering with the downward extending rim 156 being inserted into the core drain opening 134. Each of the downward extending rim 156 and the core drain opening 134 may be shaped and sized similarly such that the downward extending rim 156 is snugly received by the core drain opening 134 to prevent any of the adhesive coating 140 from seeping into the openings as it expands and cures.
Referring to
Step (a) of the method 200 may further include depositing a bead of the expanding polyurethane material to specific areas of the inner surface 116 and in specific proportions corresponding to the gap associated with the specific area. The gap 122 may generally be smaller than the bead diameter.
The method 200 may further include positioning the inner core 130 relative to the inner surface 116 of the exterior shell 110 such that the gap 122 is defined.
Throughout the specification and claims, the following terms take at least the meanings explicitly associated herein, unless the context dictates otherwise. The meanings identified below do not necessarily limit the terms, but merely provide illustrative examples for the terms. The meaning of “a,” “an,” and “the” may include plural references, and the meaning of “in” may include “in” and “on.” The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may.
Although embodiments of the present invention have been described in detail, it will be understood by those skilled in the art that various modifications can be made therein without departing from the spirit and scope of the invention as set forth in the appended claims.
This written description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
It will be understood that the particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention may be employed in various embodiments without departing from the scope of the invention. Those of ordinary skill in the art will recognize numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
All of the compositions and/or methods disclosed and claimed herein may be made and/or executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of the embodiments included herein, it will be apparent to those of ordinary skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims.
The previous detailed description has been provided for the purposes of illustration and description. Thus, although there have been described particular embodiments of a new and useful invention, it is not intended that such references be construed as limitations upon the scope of this disclosure except as set forth in the following claims.
