U.S. patent application number 12/507760 was filed with the patent office on 2010-02-18 for low step shower unit and method.
Invention is credited to Stanley R. Fasel, David W. Spiker.
Application Number | 20100037382 12/507760 |
Document ID | / |
Family ID | 41680236 |
Filed Date | 2010-02-18 |
United States Patent
Application |
20100037382 |
Kind Code |
A1 |
Spiker; David W. ; et
al. |
February 18, 2010 |
LOW STEP SHOWER UNIT AND METHOD
Abstract
A method of installing a low step entryway in a bathtub wall
structure which comprises a front wall portion, a rear wall portion
and an upper edge portion which together define an interior wall
space. A portion of the front wall is cut away to form a cutout
which is shaped in the form of the entryway which is being
installed. After the open entryway is formed, a saddle structure is
installed in the entryway. This saddle structure is shaped the same
as the entryway opening which is being provided, and it comprises a
lower middle portion forming a horizontal bottom wall, and two side
saddle members extending upwardly extending components of
alignment, with these providing side surfaces for the entryway.
Inventors: |
Spiker; David W.; (Rathdrum,
ID) ; Fasel; Stanley R.; (Rathdrum, ID) |
Correspondence
Address: |
HUGHES LAW FIRM, PLLC
5160 Industrial Place,#107
Ferndale
WA
98248-7819
US
|
Family ID: |
41680236 |
Appl. No.: |
12/507760 |
Filed: |
July 22, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61083107 |
Aug 12, 2008 |
|
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|
Current U.S.
Class: |
4/556 ;
29/428 |
Current CPC
Class: |
A47K 3/006 20130101;
Y10T 29/49826 20150115 |
Class at
Publication: |
4/556 ;
29/428 |
International
Class: |
A47K 3/02 20060101
A47K003/02 |
Claims
1. A method of installing a low step entryway in a bathtub wall
structure which comprises a front wall portion and a rear wall
portion and an upper edge wall portion which together define an
interior wall space, with the method being characterized as being
capable of installing the entryway in at least two different
situations, namely a first situation where the front and rear wall
portions are generally parallel with one another and spaced from
one another at a substantially uniform width dimension and a second
situation where at least one of the front and rear wall portions is
shaped to have a contoured wall structure portion so that at least
a portion of one of the front and rear wall portions is closer to
or further from the other, said method comprising: a. ascertaining
planned border locations of the entryway to be installed and
cutting out a separate section of the bathtub to create a cutout
region with cutout edges that comprise a lower and two side cutout
edge portions that match the border locations of the entryway; b.
providing a saddle structure comprising the following: i. a lower
central saddle section and left and right saddle sections connected
to outer opposite end portions of the center saddle section and
extending therefrom in a direction with a substantial upward
direction component; ii. each of said three saddle sections
comprising a middle plate section, with the middle plate section of
the middle saddle section providing an upwardly facing surface to
provide a person with vertical support in the entryway and said
left and right saddle sections arranged to provide left and right
inwardly facing entryway side surfaces for the entryway; iii. each
of said three saddle sections also having front and rear flanges,
each of which having a connecting edge portion connected to an
adjacent edge portion of its related plate section and extending
from its related plate section at approximately a right angle to
its related plate section; c. positioning the saddle structure over
the cutout region in a manner that the flanges of the saddle
sections at least partly overlap the perimeter locations of the
cutout region and connecting the saddle structure to the bathtub
wall structure to provide the entryway with the three middle plate
sections forming the bottom and side surfaces of the entryway.
2. The method as recited in claim 1, wherein said planned border
locations of the entryway are determined by providing a template
having an edge portion or portions corresponding to the border
location or locations and making a line location or locations on
the bathtub where it is to be cut to create the cutout region.
3. The method as recited in claim 1, wherein said saddle structure
is provided with its pair of flanges spaced sufficiently far apart
so as to be as great as a width dimension of one of the bathtub
walls in which the entryway is to be made.
4. The method as recited in claim 1, wherein the width dimension of
the pair of flanges is no less than the width dimension of the
front wall where the entryway is to be located.
5. The method as recited in claim 1, wherein the width dimension of
the flanges of the saddle structure shall be at least as large as
seven inches, and no greater than about eight inches.
6. The method as recited in claim 1, wherein each of the left and
right saddle sections are positioned on opposite sides of the
entryway, and each of these has a substantial upward alignment
component, with either or both of these left and right saddle
sections being be at a more horizontal position or a more vertical
position.
7. The method as recited in claim 6, wherein each of said left and
right saddle sections is arranged to have an upward alignment
component from about a right angle from horizontal and about
one-half of a right angle from the horizontal.
8. The method as recited in claim 1, wherein after the saddle
structure is in place in the entryway, the next step is to place
the left and right seat caps which are positioned at opposite sides
of the entryway and being positioned to conceal upper end portions
of the left and right saddle structure sections and also adjacent
portions of the adjacent upper edge portions of the front wall,
with the cap seats mounted in place.
9. The method as recited in claim 1, wherein said middle left and
right saddle sections are formed as one unitary structure as the
saddle structure.
10. The method as recited in claim 1, further comprising providing
a template tool to draw lines along the front wall along which cuts
are to be made to create an open area, comprising two sections,
namely a positioning section to raise or lower a tool, and a lower
enclosing plate section which comprises front and rear plates with
side and lower alignment edges which match the contours of the
lower and side surfaces of the saddle contour, and positioning
these to the proper elevation.
11. The method as recited in claim 1, wherein prior to positioning
and connecting the saddle structure in the operating location,
positioning one or more reinforcing members in a wall interior to
provide additional structural strength to said bathtub wall
structure in the vicinity of one or more locations where a wall
structure portion or portions has been removed.
12. The method as recited in claim 1, including placing at least
one reinforcing member at a location or adjacent to a location
where one of the saddle sections is to be located.
13. The method as recited in claim 1, including providing
reinforcement at a location where an upper end portion of one of
the right and left saddle sections is located.
14. The method as recited in claim 1, wherein with bathtub wall
being in the second category, placing one wall portion spaced from
a wall portion which it is facing so that there is a gap next to
the wall portion, said method further comprising providing a
reinforcing member that is sized to block said gap and inserting
said reinforcing member in said gap and provide caulking as
needed.
15. The method as recited in claim 1, accomplishing different sizes
of the entryway by providing a saddle structure of a larger size or
a smaller size where with the middle saddle section being
horizontally aligned at a base location, upper end portions of the
left and right saddle sections being made to be located at a higher
level for the larger entryway and at a lower level for a smaller
entryway, while maintaining the middle saddle section parallel to a
line between upper end portions of the left and right saddle
sections and positioning the saddle structure at a higher or lower
level so that the level of the support surface of the entryway is
lower or higher, respectively.
16. An apparatus which has been transformed into a low step shower
unit, comprising: a. a bathtub structure having a front wall which
has been modified so that the front wall has an entryway assembly
in which the entryway is located; b. said entryway assembly
comprising: i. a lower central saddle section and left and right
saddle sections connected to outer opposite end portions of the
center saddle section and extending therefrom in a direction with a
substantial upward direction component; ii. each of said three
saddle sections comprising a middle plate section, with the middle
plate section of the middle saddle section providing an upwardly
facing surface to provide a person with vertical support in the
entryway and said left and right saddle sections arranged to
provide left and right inwardly facing entryway side surfaces for
the entryway; iii. each of said three saddle sections also having
front and rear flanges, each of which having a connecting edge
portion connected to an adjacent edge portion of its related plate
section and extending from its related plate section at
approximately a right angle to its related plate section; c. said
saddle structure being positioned over the cutout region in a
manner that the flanges of the saddle sections overlap at least
partially the perimeter locations of the cutout region and connect
the saddle structure to the bathtub wall structure to provide the
entryway with the three middle plate sections forming the bottom
and side surfaces of the entryway.
Description
RELATED APPLICATIONS
[0001] This application claims priority benefit of U.S. Ser. No.
61/083,107, filed Jul. 23, 2008.
BACKGROUND OF THE DISCLOSURE
[0002] a) Field of the Invention
[0003] The present invention relates generally to low step shower
units, and more particularly to converting a conventional bathtub
or the like to a low step shower unit by cutting out a portion of a
containing wall and substituting it with an entryway structure.
[0004] b) Background of the Invention
[0005] Over the last twenty years or more, there have been various
designs of accomplishing this conversion of the bathtub to a low
step shower unit, and there are a number of challenges to be met.
For example, one of these challenges is that the existing wall of
the bathtub can vary substantially with regard to its shape, and
this makes it difficult to have uniformity in providing the
entryway. Also, in cutting away some of the bathtub structure to
make an entryway, this can weaken the structure. Further, there
could be a problem of leakage of the water from and around the tub
where the entryway is made.
[0006] It is toward these types of challenges that the system and
method of the embodiments of this present invention are
directed.
SUMMARY OF THE DISCLOSURE
[0007] The present invention is directed toward the method of
converting a conventional bathtub or the like to a low step shower
unit by providing the low step entryway. This invention is also
directed toward the end product itself. One of the main advantages
of the present invention is that it is possible to accomplish this
task repeatedly even though there are a wide variety of the
sidewall structures of the tub in which the entryways are to be
made.
[0008] In the method of the present invention the first task is to
cut out a portion of the tub sidewall into a configuration which is
substantially the same as the desired size and configuration of the
entryway. Then the method involves the use of what is termed a
"saddle structure" to provide the main part of the support
structure for the entryway. It comprises a lower center horizontal
saddle section which is positioned in the low central part of the
cutout to provide a support surface and left and right saddle
sections which are attached thereto, with these arranged so that
they extend upwardly and outwardly to provide side support
surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an isometric view of a typical prior art bathtub
in which an entryway is to be made;
[0010] FIG. 2 is an isometric view showing the same bathtub as in
FIG. 1, but with an entryway assembly fully installed and
operational in the front wall of the bathtub of FIG. 1;
[0011] FIG. 3 is a simplified front elevational view of FIG. 2,
showing the entryway being installed at a lower location;
[0012] FIG. 4 is a view similar to FIG. 3, but showing the entryway
being made at a higher elevation;
[0013] FIG. 5 is an isometric view of a saddle section which is a
major component used in the installation of the entryway
assembly;
[0014] FIGS. 6A and 6B are both isometric views, but taken from
somewhat different viewing locations, showing the configuration of
the two cap seats that are part of the entryway assembly of the
present invention;
[0015] FIG. 7 is an isometric view of a template tool that is used
to locate and draw the lines at which cuts are to be made in the
wall of the tub to create an entryway cutout region in the front
wall of the tub;
[0016] FIG. 8 is a side elevational view showing the template tool
of FIG. 7 being lowered toward its operating position on the tub
front wall;
[0017] FIG. 9 is a front elevational view similar to FIG. 8 showing
the template tool lowered to its operating position, and showing a
line location being made by a pencil or pen on the front wall;
[0018] FIG. 10 is a sectional view taken along line 10-10 of FIG. 9
illustrating the positioning apparatus of the template tool;
[0019] FIG. 11 is a view similar to FIG. 10 showing the same
positioning tool as in FIG. 10, but with its positioning plank
having been lowered to engage the upper edge portion of the front
wall of the bathtub in an operating position;
[0020] FIG. 12 is a view similar to FIG. 11 showing the positioning
panel being moved further downwardly to raise the template portion
of the template tool to a position to create the entryway in a more
elevated location;
[0021] FIG. 13 is a front elevational view showing the template
tool being lifted away from the front wall of the tub, and with the
location lines having been drawn on the front bathtub wall to
indicate the locations where the cuts are to be made for removal of
a portion of the front wall to form the entryway cutout region;
[0022] FIG. 14 is a view similar to FIG. 13 showing the front wall
cutout section being removed from the cutout region of the entryway
which is to be made;
[0023] FIG. 15 is a front elevational view of the front wall with
the removal of the cutout section of the bathtub wall having been
removed, and three reinforcing members (blocks) being positioned in
three different locations in the cutout portion of the front wall
of the bathtub;
[0024] FIG. 16 is a sectional view taken at line 16-16 of FIG. 15
showing a lower base reinforcing member, and an upper right located
reinforcing member, and also illustrating the overall
cross-sectional configuration of the front wall of the tub;
[0025] FIG. 17 is a sectional view taken along line 17-17 at two
locations in FIG. 15 showing two similar reinforcing blocks being
secured by screws in its operating position at two different
locations in the entryway location;
[0026] FIG. 18 is a front elevational view similar to FIG. 15
showing three different cross-sectional locations at which an
adhesive strip is located, and which could be used in caulking edge
portions at the entryway region;
[0027] FIG. 19 is a sectional view taken along section 19-19 of
FIG. 18 showing the left reinforcing block in its operating
position, and indicating two locations where caulking could be
used;
[0028] FIG. 20 is a sectional view taken along line 20-20 of FIG.
18 showing a cross section of a left saddle section with the
adhesive ribbon being used in connection with caulking;
[0029] FIG. 21 is a sectional view taken along line 21-21 of FIG.
18 and encompassing a larger view from the very top elevation of
the front wall in which the entryway is made, and extending
downwardly into the bottom of the front wall, also indicating two
locations on the base block where caulking is being used;
[0030] FIG. 22 is a view showing the entire saddle structure being
lowered into its operating position in the entryway recess that has
been made in the front wall of the tub;
[0031] FIG. 23 is a view similar to FIG. 22 showing screws (or
nails) being used to secure the saddle structure in its operating
location and it can be seen that the upper edge portions of the
side members of the saddle structure are above the top edge of the
front wall;
[0032] FIG. 24 is a side elevational view similar to FIG. 23 but
showing the two top edge portions of the saddle structure being cut
down to the level of top edge portion of the front wall;
[0033] FIG. 25 is a partial-sectional view taken along lines 25-25
of FIG. 24 showing in broken lines the entire front top and rear
portions of the outer members of the front wall, also in broken
lines showing an upper right reinforcing block located in the upper
part of the front wall, and also showing a base reinforcing member
or block in cross-section, and in its operating position at the
lower base of the entryway showing in broken lines a cross-section
of the front wall and the left reinforcing block, showing in
cross-section a lower front portion of the tub, and also showing
around the base reinforcing block the adjacent portion of the
middle saddle section;
[0034] FIG. 26 is a view similar to FIG. 25 and showing in addition
a bottom plate in the entryway having an inward slope leading into
the interior of the tub;
[0035] FIG. 27 is an isometric view similar to FIG. 6B but showing
a notch cutout of one of the flanges so that it could be placed in
its operating position at an upper right side location of the
entryway assembly;
[0036] FIG. 28 is an isometric view substantially the same as FIG.
2 but showing the right cap-seat being installed in its operating
position; and
[0037] FIG. 29 is a sectional view which is quite similar to the
view in FIG. 16; however, FIG. 29 differs in that it has an
additional reinforcing block to provide greater structural strength
in the embodiment shown in FIG. 16 and also to prevent leakage of
water if needed;
[0038] FIG. 30 is a front elevational view of the front wall of a
second embodiment of the present invention;
[0039] FIG. 31 is a sectional view of FIG. 30 taken along line
31-31 of FIG. 30;
[0040] FIG. 32 shows the front wall of a third embodiment of the
present invention where the front and rear walls are parallel to
one another and equally distant from one another, and there is the
entryway assembly installed in the wall; and
[0041] FIG. 33 is a sectional view taken along line 33-33 in FIG.
32.
DESCRIPTION OF THE EMBODIMENTS
[0042] The embodiments and methods of the system of the present
invention are directed primarily toward the task of converting an
existing bathtub to a low step shower unit. This is done by
modifying the configuration of the front wall of the bathtub by
removing a portion of the front wall of the bathtub and replacing
it with an entryway assembly which provides a low-level entryway
leading into the bathtub.
[0043] The configuration of the wall or walls of the bathtub can
vary substantially from one bathtub to another. However, the system
of this invention is arranged so that the entryway assembly is able
to be installed for substantially all tubs and/or tub/shower units
that are presently in use in the United States, and possibly in
other countries.
[0044] For example, in FIGS. 1-29 one embodiment of the present
invention is shown being used in one type of a tub where there are
differences in shape and width dimensions between upper and lower
portions of the sidewall of the tub where the entryway assembly is
to be located, and in FIGS. 30-33, a second type of a tub is shown
where the front and rear wall portions are parallel and at a
uniform width dimension.
[0045] Further, the structure of the entryway assembly of these
embodiments is such that it has substantial structural strength to
bear the weight of a large person. Also, the system is arranged so
that leakage of water from and around the tub is avoided. In
addition to that, the entire process of the removal of the portion
of the front wall of the tub and configuration are accomplished in
a relatively short time frame (e.g. a half a day), and are able to
be done rather conveniently and economically.
Introduction to the Main Components and Method of the System
[0046] In FIG. 1, there is shown one type of a conventional bathtub
10, which could be used in implementing the system of the present
invention. The tub 10 has a front wall 11 with a horizontal upper
edge portion 12 and a rear wall 19.
[0047] In FIG. 2 there is shown the same bathtub 10 as in FIG. 1,
but with the entryway assembly 16 of this first embodiment of the
present invention being completely installed and functioning. There
are three main structural components which are combined in forming
the basic structure of the entryway assembly 16, namely a saddle
structure 13, a left cap seat 14, and a right cap seat 15. Other
components will be discussed later.
[0048] In the method of the system, there is the first step of
cutting out a portion of the front wall 11 to provide a cut-out
region 17 for the entryway (see FIGS. 14 and 15). After this, these
three above-mentioned components 13, 14 and 15 are eventually
assembled in or at the cut-out region 17, as shown in FIG. 2, in
the completed assembly. In the completed entryway assembly 16,
there is the entryway 18 which is defined by a bottom entryway
surface 20 and left and right side entryway surfaces 22 and 23.
[0049] Another feature of the method of the system of the present
invention is that it is arranged so that the overall size of the
entryway 18 can be conveniently selected so that it can have a
larger or smaller overall cross-sectional area and also so that the
bottom support surface 20 of the entryway 18 can be at a lower or
higher level. By way of example, two different sized entryways 18
are shown in FIGS. 3 and 4. This will be discussed in more detail
later in this text.
[0050] To describe the saddle structure 13 in more detail,
reference is now made to FIG. 5 which shows a pre-installed saddle
structure 13 by itself ready to be installed in the front wall 11.
The total saddle structure 13 of this embodiment is a single
unitary structure, and it can be considered functionally as
comprising three quite similar saddle sections, namely, a lower
center horizontal saddle section 24 to provide vertical support for
a person, a left substantially vertical saddle section 26 to define
a left side surface, and a slanted right saddle section 28 which
extends laterally and upwardly to the right to form the complete
entryway assembly. The saddle structure 13 could be made of
fiberglass, plastic or other suitable material.
[0051] The slant of the two side saddle sections 26 and 28 could be
made the same, or these two slopes could be different from one
another. However, there is one requirement which is that each of
the two saddle side sections 26 and 28 must have a slope with a
substantial upward slope component so that each is steep enough to
provide the function of a side surface of the entryway 18.
[0052] The three saddle sections 24, 26 and 28 have the same basic
configuration. For clarification, the center saddle section 24 will
now be described in reasonable detail, giving the three components
of the central section 24 numerical designations. Then the left
saddle section 26 will be described, and those components which are
the same as, or similar to, corresponding components of the middle
horizontal section 24 will be given like numerical designations
with an "a" suffix distinguishing those of the second left vertical
saddle section 26. This same procedure will be followed in
describing the basic components of the right saddle section 28,
using the corresponding numerical designations of the middle
section 24, but with a "b" suffix distinguishing those of this
third saddle section.
[0053] With continuing reference to FIG. 5, the middle saddle
section of the center saddle section 24 comprises a rectangular
horizontally aligned bottom plate section 30 which provides the
previously mentioned upwardly facing support surface 20, a
downwardly extending front flange 32 which has a horizontally
aligned straight bottom edge surface 33, and a similar oppositely
positioned downwardly extending rear flange 34 that extends
downwardly from the rear edge portion of the middle plate 30. For
convenience, only a lower end portion of this inner flange 34 is
shown in FIG. 5, and its bottom edge is indicated at 35. Each of
the two flanges 32 and 34 are positioned in a vertically aligned
plane that is perpendicular to the plane occupied by plate section
30 so that in its operating position, each of the flanges 32 and 34
are engaging adjacent surfaces of the front and rear wall portions
of the front wall 11.
[0054] Since, as indicated above, the middle, right and left saddle
sections 24, 26 and 28 have basic structures quite similar to, or
the same as, each other, each has a center planar rectangular plate
section 30a and 30b respectively, and a front and rear laterally
extending flanges 32a and 32b, respectively, which are positioned
to be perpendicular to their plate sections 30a and 30b,
respectively.
[0055] The three front flanges 32, 32a and 32b are all
interconnected to form an entire continuous front flange, and the
three rear flanges 34, 34a and 34b are similarly connected to form
a continuous inner flange. With the entire saddle structure 13
being made as one integral structure, all three of the plates 30,
30a and 30b, and the flanges 32, 32a, 32b, 34, 34a and 34b, form a
saddle structure that is in and of itself a unitary waterproof
structure.
[0056] To now turn our attention to the two previously mentioned
cap seats 14 and 15, these are shown in FIGS. 6A and 6B which are
isometric views taken from different viewing locations and showing
the previously mentioned cap seats 14 and 15, which are (or may be)
identical, or at least be mirror images of each other. Accordingly,
in both FIGS. 6A and 6B the details of both cap seats 14 and 15
will be given the same numerical designations relative to their
component parts. To describe briefly the cap seat section shown in
FIG. 6A, there is a square (or rectangular) upper cover portion 42
and four downwardly extending perimeter flanges 43 joined to each
other in a square pattern and extending downwardly from all of the
four edge portions 44 of the upper horizontal cover portion 42.
These two cap seats 14 and 15 will be discussed later in this
text.
A Template Tool to Draw Cut Lines in the Front Wall 11 of the Tub
12
[0057] FIGS. 7-13 show a template tool 46 which is used to draw the
lines where cuts are to be made with a jigsaw or the like in the
front wall 11 of the bathtub 10 to form the access opening for the
entryway 18 in the front wall 12. As can be seen from viewing FIGS.
2, 3 and 4, the entryway 18 has a trapezoidal configuration with
the left edge at the left saddle section 26 being substantially
vertically aligned, and the right edge at the right saddle section
26 having an upward and outward slant. In order for the saddle
section 22 to be installed in the bathtub as shown in FIG. 2, it is
necessary to cut out a portion of the front wall 12 of the bathtub
that matches the contours of the saddle structure 22 which in the
installed position defines the edge surfaces of the entryway
18.
[0058] Reference is now made to FIG. 7 which shows a template tool
49 which is used to draw the lines on the front wall 11 along which
cuts are to be made to create an open area having the same overall
configuration as the saddle section 22 within reasonably close
tolerances.
[0059] The template tool shown in FIG. 7 may be made of wood or
other material and comprises functionally two sections, namely:
[0060] i) an upper vertical positioning section 48 to raise or
lower the tool; and [0061] ii) a lower enclosing plate section 50
which comprises front and rear plates 52 and 56 which have side and
lower edges which match the contours of the lower and side of inner
surfaces of the saddle contour, and are used to trace the lines
where cuts are made at the front and rear wall portions.
[0062] The two plates 52 and 56 are connected to one another by an
upper wooden plate or plank 58 (see FIGS. 10 and 11) having front
and rear edge portions which are connected to the upper edges of
the front and rear tool plates 52 and 56 as part of the positioning
section 48. There is a reinforcing plank 60 immediately below the
upper plank 58.
[0063] The upper positioning section 48 functions to raise or lower
the plate section 50 of the template tool 46 by using the four
corner height adjustment positioning bolts 62 which extend through
stationary interiorly-threaded bolt-receiving members (not shown)
in the upper plate or plank 58. By rotating the wing shaped heads
64 of the bolts, these bolts 62 can be rotated so as to be moved
upwardly or downwardly relative to the plank 58. The lower end
portions of each of the bolts 62 has a rotatable, but also axially
fixed, connection to a lower positioning member in the form of a
positioning plank 66 so that the positioning plank 66 is moved
upwardly and downwardly with the upward and downward movement of
the lower ends of the bolts 62. In this manner, the entire template
tool 46 can be positioned at the desired height location by
engaging the positioning plank 66 on the top edge surface of the
front wall 11 of the bathtub and rotating the bolts 62 to raise or
lower the entire enclosing plates 52 and 54 and the plank 58.
[0064] Thus, by moving the lower positioning plank 66 downwardly
from the upper plank 58, the plates 52 and 56 of the plate section
52 can be raised. Thus, it can be seen that in order to make a
larger entryway 18 with greater depth, the entire plate section 50
can be brought to a lower position which will place the bottom
middle section 24 of the through entryway at a lower location and
have the two side sections 28 and 26 spaced further from one
another at their upper end portions. Or by raising the template
plate section 50, the smaller opening of FIG. 4 could be made.
[0065] To illustrate this, reference is made to FIGS. 9, 10, 11 and
12. In FIG. 10, the positioning plate 66 is at a higher level,
which causes the positioning plate 66 to be spaced above the top
surface 14 of the front wall 12 of the bathtub 10, and the plate
section 10 is at a low position. In FIG. 11, the bolts 62 have been
rotated to lower the positioning plate 66 so that it is now
engaging the upper wall surface 14 and is just beginning to raise
the wall section 50 of the template tool 48 upwardly. Then in FIG.
12, the positioning plate 66 has been lowered yet further to raise
the wall section 50 yet higher.
[0066] It is to be understood that the terms such as "plate" or
"plank" are not to be interpreted in accordance with the dictionary
definitions, but are to be interpreted to be members which perform
the functions as described.
[0067] To turn our attention back to FIG. 9, we will assume that
the template tool 46 has been used to bring the wall section 50 to
a desired low location. Then a marking pen or pencil 68 is used to
draw the lines 74 at the location where the cuts are to be made
(see FIG. 13), with these lines 74 being along bottom and side edge
portions of the front template wall 48 to indicate the location
where the front bathtub wall 11 is to be cut. Similar markings are
also made at the opposite side surface of the front bathtub wall.
If the rear wall portion of the front wall 11 has an irregular
shape, the markings on the outer side of the wall 11 could be used
as a guide to make matching markings on the rear wall portion.
[0068] When the cutting lines 74 have been drawn on the bathtub
wall 11, the template tool is removed (see FIG. 13), and tape can
be placed first inside the lines 74 so that the jigsaw or other
cutting tool could use the tape as a guide. Then the next step is
to cut through the front and rear wall portions of the front wall
10 along the lines indicated at 74 and along the back side of the
wall 11. Then the separated section 75 of the front wall is removed
(see FIG. 14) to leave a cutout region 17 defined by bottom, left
and right edge portions.
[0069] At this point, the saddle section 22 should be temporarily
placed into the earlier mentioned cutout region 17 to be sure that
the saddle structure 22 is making a proper fit with the cutout
region 17. The upper surface of the saddle structure 22 should be
even with the upper edge surface 14 of the front wall 12.
Therefore, if the saddle structure 22 does extend higher than that
level of the cutout region 17, the jigsaw can again be used to cut
off the upper portion or portions of the saddle structure 13 that
is or are above the upper edge 14 of the front wall 12 of the
bathtub 10. Or, this could be done later, but before the cap seats
14 and 15 are put in place (see FIGS. 23 and 24).
[0070] After the fit of the saddle structure has been found to be
satisfactory, the saddle structure 13 is removed temporarily, and
this brings us to the next steps which are shown in FIG. 15 and
following.
Background Information Relating to the Initial Procedures in the
Installation of the Entryway Assembly
[0071] In the portion of the text that follows there will be
discussions of items which would involve the front wall 11, and to
have consistent terminology the two wall portions that make up the
front wall structure will simply be called the "front wall portion
45" and the other wall portion of the rear of the wall 11 will be
called the "rear wall portion 46". The contained region between the
two will be designated the "front wall void 47".
[0072] It is evident that cutting out this rather substantial
portion of the front wall 11 to form the cutout region would to
some extent weaken the structure of the bathtub 10. Further, since
the interior of the wall structure of the bathtub 10 would usually
be enclosed empty space (i.e., would be a void), and since forming
the cutout region 17 opens up a substantial portion of the void or
empty chambers of the front wall 11, then it would be highly
desirable to arrange the installation of the entryway structure 22
so that the interior region of the front wall 11 is closed off so
that water would not seep in and/or out. This brings us first to
FIG. 15.
[0073] It is believed that a better understanding of the following
text relating to completing the installation will be obtained by
first reviewing some background information relating to the varying
configurations of the walls of the tub 10. Earlier in this text, it
was stated that one of the features of the embodiments of this
invention is that they are adapted for use with bathtubs having
varying configurations of the wall of the bathtub in which the
entryway installation is accomplished. It is believed that a
clearer understanding of how this is accomplished with the present
system will be gained by selecting at least one example of a
bathtub wall which has some variations from a bathtub wall that
would simply have totally planar parallel side surfaces spaced
evenly from one another.
[0074] Accordingly, in the following discussion and in the
drawings, the front wall 11 of the tub, which is being described in
this text and shown in the drawings, has deviations from the tub
wall with the planar parallel wall configuration. One typical
example has been selected, and this selected wall construction will
now be discussed briefly with reference to FIG. 16.
[0075] FIG. 16 is a sectional view of the total front wall 11 taken
along line 16-16 of FIG. 15, and this front wall 11 is the front
wall in which the entryway assembly 16 is being placed. This front
wall 11 has a front substantially planar front wall portion 45 and
a rear "non-regular" wall section which is called the rear wall
portion 46 The rear wall portion 46 can be considered as having
differing upper and lower inner wall portions 84 and 85, with the
upper inner wall portion 84 being positioned closer to the outer
wall portion 82, and the lower inner wall portion 85 being spaced
further from the outer wall section 82. Then these two inner wall
portions 84 and 85 are joined by an interconnecting horizontally
aligned connecting shoulder 86. The lower end portion of the inner
wall section 83 terminates in a rounded lower connecting portion 87
that connects to the lower bottom wall 88 of the bathtub.
[0076] With that background information being given, let us now
return to the subject of completing the installation of the
entryway assembly 16.
Proceeding with the Initial Installation Procedures
[0077] In FIG. 15, there are three reinforcing members 90, 91 and
92 which are shown being placed in positions in the front wall 11
prior to the time that the saddle structure 13 is placed in its
completed operating position. In addition to being used for
reinforcement, these reinforcing members 90, 91, and 92 may also
have an additional function of closing off voids in the front wall
12 to make them water leak proof. This is done in large part by
sizing and shaping the reinforcing members as rectangular prisms
(i.e., in the form of a "block") which could be made from processed
wood, outdoor component material, or other waterproof material that
is then inserted adjacent to its related void area. Alternatively,
the block could, if needed, deviate from the rectangular prism
configuration. For convenience, these reinforcing members will
simply be referred to as "blocks", and this term "blocks" is to be
interpreted more broadly to a member which would occupy the region
to provide support and, if needed, prevent leaking. Further, these
blocks are, or can be, selectively sealed with caulking or the
like, or other sealants, to prevent water leakage.
[0078] The originators of the present invention have found that a
practical course of action is to have various shaped "blocks" or
other wood members, and shaping some of these at the actual
location where the apparatus of the invention of the embodiment is
being installed. This way any measurements can be taken and the
wood members could be made to size and shape. For example, a
stationary power saw could be used, or a hand held saw (e.g. a
circular saw). With the building materials which are currently made
and also the structural characteristics of calking materials and
the like enable these to be installed so as to provide a waterproof
characteristic and also provide adequate structural support.
[0079] To proceed further with the description of the blocks, as
shown in FIG. 15, there is a lower rectangular elongate base block
90 which is shown in full lines being moved to an installed
operating position that is shown in broken lines in FIG. 15, and in
full lines in FIGS. 16, 21, 25 and 26. Specifically, in FIG. 16 the
forward positioned elongate surface of this block 90 bears against
a lower part of the front wall portion 82 and the rear elongate
surface 94 of the block 90 bears against a lower end portion of a
rear wall portion 85 at a junction location where a lower rear
portion of the rear wall portion of the bathtub is beginning to
enter into a 90.degree. downward bend portion 87 to transition into
the horizontal tub floor 88 (see FIGS. 16 and 21). Screws 96 are
inserted at front and rear sides of the block 90 (see FIG. 16)
locations to secure the block 90 in place.
[0080] The remaining reinforcing members (i.e., the two blocks 91
and 92) are very similar to one another, and we will direct our
attention first to the left reinforcing member 91 (which will be
called the "block 91").
[0081] With reference to FIGS. 15, it can be seen that the block 91
is being moved from an outer location (solid lines of 91) to an
inner left location (solid lines 91). This block 91 is also shown
in a sectional view of 17-17, looking downwardly, and is also seen
in a larger size in the view of FIG. 21, which is taken from the
location line 21-21 being shown in FIG. 18. In viewing FIG. 21, it
can be seen that the block 91 is between an upper portion of the
outer wall portion 12 and an upper inner wall portion 84, and just
below a top wall portion 97. In FIG. 17, it can be seen it is
secured in place by screws 96.
[0082] Then there is the second similar block 92 which can be seen
in FIG. 15, as being located on the right side of the installation
opposite from the block 91. This block 92 has the very same
cross-section as the block 91 as shown in the view at 17-17.
Further, it can be seen in FIG. 16 (which is at a section line
taken along line 16-16 of FIG. 15) that the block 91 is in an upper
position from the upper edge surface of the adjacent wall portions
of the outer and inner wall portions 82 and 84 (see FIG. 21).
[0083] The term "caulking", whether used as a noun or verb, is not
be limited to a dictionary definition, but is intended to include
the various techniques or practices which could be used to seal
liquid leaks or prevent any leaks from occurring.
[0084] Earlier in this text, it was pointed out that caulking would
be used at various locations to make the entryway assembly 16
sufficiently waterproof so that there would not be leakage from or
around the region of the bathtub 10. In general, some sort of
caulking or similar steps would be taken where there is an
interface between two separate components.
[0085] Reference is made to FIGS. 18 through 21 to discuss the
various applications of caulking in the system of the present
invention.
[0086] To discuss this further, reference is first made to FIG. 21
which is a cross-sectional view of the base block 90 that is
positioned between the outer and inner walls 45 and 46 of the front
wall 11. It can be seen in FIG. 21 that at the upper edge portions
where the side surfaces 93 and 94 of the reinforcing block 90 bear
against the outer and inner walls 82 and 83, there are two caulking
locations 110 and 112 which are shown simply as very small circular
caulking portions. These caulking applications 110 and 112 extend
entirely around the upper perimeter of the block 90 to prevent any
leakage.
[0087] Attention is next directed to FIG. 19 which shows the upper
reinforcing block 91 which is positioned between the front and rear
upper wall portions 45 and 46. It can be seen that there are two
caulking applications at 114 and 116 at the juncture location where
the sides of the reinforcing block 91 press against the adjacent
interiorly facing surfaces at the front edges of the wall sections
83 and 84. In finalizing the installation of the entryway assembly,
the saddle structure 13 is pressed downwardly into the entryway
opening. Surface portions of the saddle structure 13 press against
these caulking applications to press the caulking material into the
creases or seams that exist between the components which are
pressing against one another.
[0088] It will be noted in FIG. 18 that the cross-section at 19-19
cuts through the left block 91 and the adjacent walls 82 and 84.
Then, again with reference to FIG. 18, if we look at the section
wall 19-19 and then observe the section line at 20-20 we see a
different situation. The location of the section line 19-19 is
through the block 91, and the caulking 114 and 116 can be wedged
into the juncture location of the walls 82 and 84 and the block 91.
The section line through 20-20 is a location between the two walls
82 and 83. It can be seen that in the section lines of FIG. 20,
there are not only the two caulking applications 118 and 120, but
there is also two items identified by numerals 122 and 124.
[0089] These numerals 122 and 124 are to indicate two portions of
adhesive ribbons which can be used to provide a better seat for the
application of the caulking.
[0090] To discuss these adhesive ribbons 122 and 124 further,
reference is made to FIG. 18. The numerical designation 122 which
is used for the adhesive ribbon is shown in FIG. 18 at a left
location 122, a bottom location 122, an upper right location at
122, and there is a ribbon end portion at 122 in FIG. 18 that is
illustrating the ribbon end portion as being out from engagement
with the adjacent portion part of the saddle structure simply to
show that it is a separate flexible ribbon. The other ribbon 124 is
placed in a manner similar to the first ribbon 122, but on the
opposite side. By placing these two ribbons 122 and 124 as
described above, there is provided a base to which the caulking
application could be applied.
[0091] After all of the applications of caulking have been made as
discussed previously and with reference to FIGS. 18 through 21, the
next step would be, as shown in FIG. 22, to insert the saddle
structure 13 into the entryway opening, and press it against the
three main surfaces 20, 22 and 23 (middle, left and right) in the
entryway region. The pressure of the surfaces of the saddle
structure 13 will cause the caulking itself to be pressed into the
juncture areas and any seams which are potential routes for water
leakage.
[0092] When this has been accomplished, then, as shown in FIG. 23,
screws or nails 96 are inserted through the plate portions of the
saddle structure 13 and to penetrate into the reinforcing blocks 91
and 92 to hold the saddle structure 13 in place.
[0093] With the saddle structure 13 being secured in place, the
final step is to install the two cap seats 14 and 15 onto the upper
surface portions of the front wall immediately next to the side
walls of the assembly 16. In FIG. 28 the left cap seat 14 is shown
as being already installed, and the right cap seat 15 is positioned
at an upper location to be lowered into its proper location in the
assembly 16.
[0094] Reference is made to FIG. 27, showing that a notch 130 has
been cut to remove a small section 132 of one of the side flanges
43 so that in placing the cap seat 15 in its proper location, the
upper edge portion 12 of the front wall 11 will fit into the notch
130.
[0095] In preparation for the installation of the cap seat 15, an
adhesive caulking material 136 is distributed over the entire upper
surface portion of the upper edge surface portion 136 of the wall
11, and also in the area of the adjacent upper portion panel
structure. Then the entire cap seat 15 is lowered into place and
becomes bonded to become part of the entryway assembly 16.
[0096] With this last task, with the cap seat 15 completed, the
restructured tub with its new entryway 18 is ready for full
operation.
A Brief Presentation of Location Relationships
[0097] FIG. 25 is a sectional view 25-25 as taken through a middle
portion of the entire assembly 16 as shown in FIG. 24.
[0098] At the very bottom of FIG. 25 there are several components
shown in cross-section at a middle section line at a middle
location of the base block 90. These are the base block 90, the
middle saddle section 24 with its horizontal plate 25, and its
front and rear flanges 24, 32 and 34 of the saddle structure. Also,
at the bottom right-hand portion of FIG. 25, there is shown a
portion of the bottom wall 88 of the bathtub 10. There is also
shown the plate section 24 of the left saddle section 26, and this
extends all the way to the top of FIG. 25.
[0099] Attention now is directed to FIG. 29 which shows the
configuration of the front wall 11 and the arrangement of the
components rather clearly. However, FIG. 29 differs somewhat from
FIG. 25 in that in addition to the block 21 at the top of FIG. 25,
there is an addition to that, a second lower block 97 which presses
against front and rear walls 45 and 46 to provide greater overall
structural strength. This is simply to illustrate the point that
throughout the various arrangements shown in this patent
application, there can be additions of blocks and/or at a multitude
of locations to provide a number of benefits, such as a system in
making certain arrangements more waterproof, and structural
strength.
A Second Embodiment of the Present Invention
[0100] The second embodiment of the present invention will now be
described with reference to FIGS. 30 through 33. Components of this
second embodiment that are the same as, or similar to, components
of the earlier embodiment will be given like-numerical designations
with a "d" to indicate those are of the second embodiment.
[0101] Earlier in this text, the present invention was introduced
by stating that it is capable of installing the entryway assembly
in the front wall of the tub in all, or most all, of the tubs that
are currently available in the United States, and possibly outside
the United States. In the first embodiment which is described
earlier in this text, the situation is presented where the wall 11
of the tub has a cross sectional configuration where the upper and
lower parts of the wall differ from one another. It was pointed out
that this creates certain problems. In the first embodiment it is
shown how the method can be adapted to install the entryway
assembly under those circumstances.
[0102] It was indicated in the third paragraph under the heading
"Description of the Embodiments" that FIGS. 30-31 would show the
second type of tub where the front and rear wall portions are
parallel and at a uniform width dimension. The following text
describes, in conjunction with the FIGS. 30-33, the manner in which
the entryway assembly 18d is provided in this second
embodiment.
[0103] In FIG. 31, there is shown a cross section of the front wall
11d. There are front and rear wall portions 45d and 46d, and both
of these have a planar configuration and these are at equal
distances from one another.
[0104] This same front wall is shown in side elevational view in
FIG. 30, and it can be seen that the cutout from the wall has
already been accomplished, and the saddle sections 24d, 26d, and
28d have been indicated in FIG. 30.
[0105] FIG. 30 shows the front wall 11d where the entryway has
already been cut out, but the saddle section 13d has not yet been
installed.
[0106] Now we turn our attention to FIG. 31 which is a sectional
view of the bathtub taken along the middle location indicated at
31-31. It becomes evident in viewing the steps taken in the first
embodiment that the task of installing the saddle section 13d in
this second embodiment is substantially simplified. Also, in this
second embodiment, the various reinforcing blocks and the caulking
could be utilized much in the manner of the first embodiment, but
the task is greatly simplified.
[0107] The inventors of the present patent application have
previously done surveys of the various types of bathtubs which are
available in the United States, and the width dimension of the
walls of these bathtubs at the locations where the entryway would
be made were found to be slightly over 71/4 inches and slightly
less than 8 inches. Accordingly, in structuring the apparatus of
the present invention, the spacing between the inside surfaces of
the front and rear flanges 32 and 34, 32a and 34a and 32b and 34b,
as indicated at "F" in FIG. 31, is presently 8 inches. Of course,
this would be, in all likelihood, modified if the dimensions of the
tub walls would also change.
[0108] In FIG. 31 it is shown that in the upper portion of front
wall 11d, there is a rectangular shaped reinforcing member 92d
which is installed in the upper portion of the front wall 11d, and
with the front and rear wall portions 45d and 46d being parallel to
one another, there is automatically a proper fit of the reinforcing
member 92d. Also, as needed, the caulking can be accomplished, and
by way of example, two of these caulking locations 110d and 112d
are indicated in FIG. 31.
[0109] FIG. 32 is essentially the same as 30a, except that it is
shown that the saddle structure 13d has been installed. Also, FIG.
33 is simply a sectional view taken at 33-33 from FIG. 32. It is
believed that further comments on FIGS. 32 and 33 is not
needed.
[0110] While the present invention is illustrated by description of
several embodiments and while the illustrative embodiments are
described in detail, it is not the intention of the applicants to
restrict or in any way limit the scope of the appended claims to
such detail. Additional advantages and modifications within the
scope of the appended claims will readily appear to those sufficed
in the art. The invention in its broader aspects is therefore not
limited to the specific details, representative apparatus and
methods, and illustrative examples shown and described.
Accordingly, departures may be made from such details without
departing from the spirit or scope of applicants' general
concept.
* * * * *