US 11,813,226 B2
Spa shell reinforcement systems and methods
Robert Santos, South Jordan, UT (US); Richard Alex Eddington, South Jordan, UT (US); Evan Smail, West Jordan, UT (US); Mark McLane, Lehi, UT (US); Eric Hales, Eagle Mountain, UT (US); and Michael Adams, West Jordan, UT (US)
Assigned to Bullfrog International, LC, Herriman, UT (US)
Filed by BULLFROG INTERNATIONAL, LC, Herriman, UT (US)
Filed on Nov. 11, 2021, as Appl. No. 17/524,105.
Prior Publication US 2023/0142127 A1, May 11, 2023
Int. Cl. A61H 33/00 (2006.01)
CPC A61H 33/6005 (2013.01) [A61H 33/0087 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A method for reinforcing a spa shell, the method comprising:
molding a thermoplastic sheet into a predetermined spa shell shape to form a shell for containing water;
spraying at least two layers of polyurethane onto an underside of the spa shell, forming an inner layer of rigidizer that is 0.2 centimeters to 1 centimeter thick;
placing at least one shield on the underside of the spa shell at a jet predetermined location to prevent a foam support layer from forming over the jet predetermined location;
applying a foam support layer that is 0.5 centimeters to 3 centimeters thick on the underside of the spa shell over the inner layer of rigidizer, the foam support layer extending from a bottom side of the underside of the spa shell, across at least one sidewall of the underside of the spa shell to a lip of the spa shell, the foam support layer forming at least one rib along the sidewall of the underside of the spa shell; and
spraying at least two layers of polyurethane onto the underside of the spa shell, forming an outer layer of rigidizer that is 0.25 centimeters to 1 centimeter thick.