Method of forming fluid channels on a bathtub

Patent metadata

Field	Value
Publication number	US-11433627-B2
Application number	US-201916577023-A
Country	US
Kind code	B2
Filing date	Sep 20, 2019
Priority date	Sep 21, 2018
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

A method of forming a bathtub includes forming a core from a core material, coupling the core to a bathtub shell, applying a reinforcing material to the bathtub shell over the core to form a reinforcement structure, forming one or more openings in the bathtub shell, and substantially removing the core from between the bathtub shell and the reinforcement structure to define one or more fluid channels of the bathtub.

First claim

What is claimed is:

1. A method of forming a bathtub, the method comprising:
forming a core from a core material;
coupling the core to a bathtub shell;
applying a reinforcing material to the bathtub shell over the core to form a reinforcement structure;
forming one or more openings in the bathtub shell; and
substantially removing the core from between the bathtub shell and the reinforcement structure to define one or more fluid channels of the bathtub.

2. The method of claim 1 , wherein substantially removing the core includes directing a fluid through the one or more openings of the bathtub shell.

3. The method of claim 1 , wherein the core material is dissolvable, and wherein substantially removing the core includes at least partially filling the bathtub shell with fluid to direct fluid to the core through the one or more openings, so as to substantially dissolve the core.

4. The method of claim 1 , wherein the core material includes a wax, and wherein substantially removing the core includes substantially melting the core by heat energy from curing of the reinforcing material.

5. The method of claim 4 , wherein the one or more openings are configured to direct the substantially melted core away from the bathtub shell.

6. The method of claim 4 , wherein the one or more openings are formed in the bathtub shell before coupling the core to the bathtub shell.

7. The method of claim 1 , wherein the core material is dissolvable.

8. The method of claim 1 , wherein the core material is corn starch.

9. The method of claim 1 , wherein the reinforcing material includes a fiber reinforced polymer.

10. A method of forming a bathtub, the method comprising:
forming a core from a core material, wherein the core material is at least one of a dissolvable material or a phase-changeable material;
coupling the core to a bathtub shell;
applying a reinforcing material to the bathtub shell over the core to form a reinforcement structure;
forming one or more openings in the bathtub shell to access the core; and
substantially removing the core from between the bathtub shell and the reinforcement structure to define one or more fluid channels of the bathtub.

11. The method of claim 10 , wherein substantially removing the core includes directing a fluid through the one or more openings.

12. The method of claim 10 , wherein the core material is dissolvable, and wherein substantially removing the core includes at least partially filling the bathtub shell with fluid to direct the fluid to the core through the one or more openings, so as to substantially dissolve the core.

13. The method of claim 10 , wherein the core material includes a wax, and wherein substantially removing the core includes substantially melting the core using heat energy from curing of the reinforcing material.

14. The method of claim 13 , wherein the one or more openings are configured to direct the substantially melted core away from the bathtub shell.

15. The method of claim 13 , wherein the one or more openings are formed in the bathtub shell before coupling the core to the bathtub shell.

16. The method of claim 10 , wherein the core material is dissolvable.

17. The method of claim 10 , wherein the core material is corn starch.

18. The method of claim 10 , wherein the reinforcing material includes a fiber reinforced polymer.

19. A method of forming a bathtub, the method comprising:
forming a core from a core material;
coupling the core to a bathtub shell;
applying a reinforcing material to the bathtub shell over the core to form a reinforcement structure; and
substantially removing the core from between the bathtub shell and the reinforcement structure to define a fluid channel of the bathtub.

20. The method of claim 19 , wherein the fluid channel is at least one of an overflow channel or an air channel of the bathtub.

Assignees

• Kohler Co

Inventors

• Stout Kenneth

Classifications

• B29L2031/7692

  Baths · CPC title

• B29K2309/08

  Glass · CPC title

• A47K3/02

  Baths (combined with showers A47K3/20) · CPC title

• B29C70/70

  Completely encapsulating inserts {(B29C70/86 takes precedence)} · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title