U.S. patent application number 14/057049 was filed with the patent office on 2015-04-23 for molded shower assembly.
This patent application is currently assigned to Alpha Systems, LLC. The applicant listed for this patent is Alpha Systems, LLC. Invention is credited to Michael Vagedes.
Application Number | 20150107018 14/057049 |
Document ID | / |
Family ID | 52824873 |
Filed Date | 2015-04-23 |
United States Patent
Application |
20150107018 |
Kind Code |
A1 |
Vagedes; Michael |
April 23, 2015 |
MOLDED SHOWER ASSEMBLY
Abstract
An injection molded shower stall assembly or bathtub assembly
particularly for use in a recreational vehicle includes an
injection molded tub or shower base, which includes an integrally
formed drainpipe which is externally threaded and adapted to easily
and permanently be connected to plumbing for the recreational
vehicle. Injection molded walls are formed to surround either the
shower stall or tub. The injection molded walls have lower edges
that interfit with edges of the tub or shower stall in a way which
prevents water from flowing behind the preformed walls and holds
the lower edges of the preformed walls in position, eliminating the
need for any type of penetrating fastener along the base of the
walls. The walls are formed in multiple sections that fit one on
top of the other, with interfitting lower and upper edges, again to
reduce the need for penetrating fasteners and to hold the sections
in position.
Inventors: |
Vagedes; Michael; (Florence,
KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alpha Systems, LLC |
Elkhart |
IN |
US |
|
|
Assignee: |
Alpha Systems, LLC
Elkhart
IN
|
Family ID: |
52824873 |
Appl. No.: |
14/057049 |
Filed: |
October 18, 2013 |
Current U.S.
Class: |
4/584 ;
4/613 |
Current CPC
Class: |
A47K 3/161 20130101;
A47K 3/02 20130101; B60R 15/02 20130101; A47K 3/284 20130101; A47K
3/28 20130101 |
Class at
Publication: |
4/584 ;
4/613 |
International
Class: |
A47K 3/02 20060101
A47K003/02; A47K 3/28 20060101 A47K003/28 |
Claims
1. A plastic shower assembly comprising: a one piece molded base
having a drain; said drain having an integral externally threaded
connection molded as part of said base extending downward and
adapted to connect to an internally threaded pipe; said base
including a continuous upwardly extended peripheral edge extending
along at least two sides of said base; said edge including a first
rear flange and a first forward flange and a first channel between
said first rear flange and said first forward flange; a first wall
section adapted to mate with said continuous upwardly extended
peripheral edge and having in a second wall section adapted to mate
with said first wall section; said first wall section having a rear
surface and a forward surface, and having a first lower edge having
a second rear flange spaced from said first surface and adapted to
fit into said first channel; and a second forward flange adapted to
extend over said first forward flange of the peripheral edge of
said base, with said first forward flange resting in said second
channel of said lower edge; said second wall section having a
continuous upper edge having a third rear flange and a third
forward flange separated by a third channel.
2. The assembly claimed in claim 1 wherein said first upper edge of
said first wall section includes first and second corners, said
first and second corners having mounting tabs adapted to rest flush
with said rear surface and said second wall section includes a
lower edge having first and second corners adapted to cover said
first and second mounting tabs.
3. The assembly claimed in claim 2 wherein said assembly further
includes a third wall section having integrally formed first and
second walls having a lower edge adapted to mate with and extend
over an upper edge of said second wall section, said lower edge
having a fourth rear flange and fourth inner flange with a fourth
channel therebetween, said upper edge of said second panel having a
flange adapted to rest within said channel, thereby holding the
lower edge of said third section in position; said third section
further including mounting holes along an upper edge of said third
wall section.
4. A plastic shower assembly comprising: a one piece molded base
having a drain; said base including a continuous upwardly extended
peripheral edge extending along at least two sides of said base;
said edge including a first rear flange and a first forward flange
and a first channel between said first rear flange and said first
forward flange; a first wall section adapted to mate with said
continuous upwardly extended peripheral edge and having in a second
wall section adapted to mate with said first wall section; said
first wall section having a rear surface and a forward surface, and
having a first lower edge having a second rear flange spaced from
said first surface and adapted to fit into said first channel; and
a second forward flange adapted to extend over said first forward
flange of the peripheral edge of said base, with said first forward
flange resting in said second channel of said lower edge; said
second wall section having a continuous upper edge having a third
rear flange and a third forward flange separated by a third
channel.
5. A tub assembly comprising a molded tub, said molded tub having
four sides, three of said sides including a continuous rear flange
extended along said three sides and adapted to rest against three
side walls; a second continuous flange forward of said rear flange;
a first wall section having three walls, said wall section having a
rear flange and a forward flange with a channel therebetween, said
lower edge of said wall section adapted to fit onto said tub with
said forward flange of said tub resting in said first channel of
said wall section, thereby holding said lower edge of said wall
section in position, said wall section further including fastener
openings along an upper section of said wall section.
6. The tub assembly claimed in claim 5 wherein said wall section
includes three separate molded panels, a middle panel and mirror
image front and rear panels, said middle panel having first and
second vertical flanges along first and second opposed sides, said
front and rear panels having a vertical channel adapted to receive
said vertical flanges of said middle panel, thereby forming a first
continuous three sided wall section.
7. The tub assembly claimed in claim 6 wherein said tub assembly
further includes a second continuous wall section having a lower
edge adapted to interfit with an upper edge of said first three
sided wall sections,
8. The tub assembly claimed in claims 7 wherein said second
continuous three sided wall section includes forward and rearward
panels and a side panel, wherein said forward and rearward panels
snap fit to said side panel.
Description
BACKGROUND OF THE INVENTION
[0001] Showers and bathtubs in recreational vehicles typically
include a molded base and some type of water impervious laminate
applied to the walls, which direct water to the molded base.
Typically the molded base has a drain opening and a drainpipe is
fastened to the opening and connected to plumbing.
[0002] The laminates used are typically relatively flimsy but they
are used because they are lightweight, inexpensive and can
withstand the vibrations of a moving vehicle. The drain, however,
does present problems because there is generally no access to the
drainpipe once the tub or stall is installed. One cannot see if
there is any leakage occurring until it works its way through the
floor. Also, the vibrations produced by the moving vehicle can
easily cause the drainpipe to become loose, making leaks a
significant concern.
SUMMARY OF THE INVENTION
[0003] The present invention is premised on the realization that a
more effective, aesthetically appealing shower or tub can be formed
by molding the tub or the base with an integral threaded drainpipe.
The base or tub further includes peripheral flanges which mate with
injection molded sidewalls. The sidewalls are formed in sections
that allow them to be easily installed within the vehicle in a
stacked configuration to give the desired height of the sidewalls.
These sidewalls, because they inter-fit, prevent water from
leaking. Because they are injection molded, they are much stronger
than typical laminates used in these applications. Further,
fastening holes can be provided which can be easily covered by an
adjacent section which again provides an aesthetically clean
appearance. In one embodiment, they can be formed with three
integral walls which prevents water from leaking at the
corners.
[0004] The objects and advantages of the present invention will be
further appreciated in light of the following description of the
drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective exploded view of the present
invention;
[0006] FIG. 2 is a perspective view of the present invention;
[0007] FIG. 3 is an enlarged perspective view of area 3 of FIG.
1;
[0008] FIG. 4 is an enlarged perspective exploded view of area 4 of
FIG. 1;
[0009] FIG. 5 is a cross-sectional view taken at lines 5-5 of FIG.
2;
[0010] FIG. 6 is a cross-sectional view taken at lines 6-6 of FIG.
2;
[0011] FIG. 7 is a cross-sectional view taken at lines 7-7 of FIG.
2;
[0012] FIG. 8 is a bottom side perspective view of the shower base
of the present invention;
[0013] FIG. 9 is a perspective view, partially exploded, of an
alternative embodiment of the present invention utilizing a
bathtub;
[0014] FIG. 10 is a perspective view showing assembly of the
sidewalls of a alternative embodiment of FIG. 9 of the present
invention;
[0015] FIG. 11 is a perspective view, partially exploded, of the
embodiment shown in FIG. 10;
[0016] FIG. 12 is a perspective view of the alternative embodiment
shown in FIG. 10;
[0017] FIG. 13 is an enlarged view of area 13 of FIG. 10;
[0018] FIG. 14 is an enlarged view of area 14 of FIG. 11;
[0019] FIG. 15 is an enlarged view of area 15 shown in FIG. 11;
[0020] FIG. 16 is cross-sectional view taken at lines 16-16 of FIG.
12;
[0021] FIG. 17 is a cross-sectional view taken at lines 17-17 of
FIG. 2;
[0022] FIG. 18 is a cross-sectional view taken at lines 18-18 of
FIG. 2;
[0023] FIG. 19 is a cross-sectional view taken at lines 19-19 of
FIG. 2; and
[0024] FIG. 20 is a bottom perspective view of the bathtub shown in
FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention can be in the form of a shower stall,
as shown in FIGS. 1-8 or a bathtub as shown in FIGS. 9-20.
[0026] As shown in FIG. 1, a shower stall assembly 10 includes a
base 12, a first wall section 14, a second wall section 16 and a
third, upper wall section 18. The base 12 includes a floor 20 and a
bottom surface 22 and raised sidewalls 24. The front 26 is open and
would typically be enclosed by a glass enclosure or the like.
[0027] Base 12 further includes a drain 30 which is molded as part
of the base 12 and includes an integral, externally threaded
drainpipe 32 extended below floor 20.
[0028] As shown in FIGS. 1 and 2, the base 12 rests on its bottom
surface 22 mounted directly to the floor or can be raised above the
floor of the recreational vehicle. In this latter case, a spacer 34
would be attached to the other edge of the base 12 as a trim
piece.
[0029] The base further includes a raised peripheral edge 38, which
runs continuously on first side 40 and second side 42 and
(optional) rear corner side 44. Peripheral edge 38 includes a first
continuous rear flange 46 and a first continuous forward flange 50,
separated by a first channel 48. As described hereinafter, this
allows the first wall section 14 to be mounted on the base 12,
forming a connection that prevents water from flowing to the
backside of the shower stall.
[0030] The first wall section 14 includes a first wall 54, a second
wall 56 and a corner section 58. The corner sections are optional
as first wall 54 can be connected to second wall 56 as long as it
conforms to peripheral edges 38. The front surface 60 and wall
section 14 is designed to direct water into the base 12 and the
rear surface 62 is intended to be mounted against a wall of the
recreational vehicle. First wall section 14 includes a bottom edge
64 and a top edge 66. The bottom edge includes a second rear flange
68 and a second forward flange 70, with a second channel 72
therebetween.
[0031] The top edge includes an upwardly extending flange 74, Also
on either side of top edge 66 are first and second corners 76, 78,
respectively. Each corner 76, 78 includes first and second
attachment tabs 80, 82, which are designed to lie flush against the
wall of the recreational vehicle, Top edge 66 further includes a
first ledge 84 adjacent upper flange 74.
[0032] The second wall section 16 likewise has a bottom edge 88 and
a top edge 90. Bottom edge 88 includes a continuous third rear
flange 92 and a forward edge 93. As shown in FIG. 7, the upper
flange 74 of the lower wall section fits between the third rear
flange 92 of the bottom edge 88 and the forward edge 93. The upper
edge 90 of the second wall section 16 is identical to the upper
edge 66 of the first wall section 14 and, likewise, the bottom edge
94 of third wall section 18 is identical to the bottom edge 88 of
the second wall section 16 and therefore not described further in
detail. As shown, the third wall section 18 includes one or more
soap dishes 98 and the upper edge 96 is held in position by barbed
plugs 97, which extend through though top edge 96 into the walls of
the recreational vehicle. However, any suitable fastener can be
used.
[0033] To install the shower stall of the present invention, the
base is positioned as desired on the floor (not shown) of a
recreational vehicle. In certain recreational vehicles, there is an
area under the floor that allows for plumbing. In this case, the
base 12 would be positioned on the floor (not shown) with drainpipe
32 extended through a hole (not shown) in the floor. If there is no
area for plumbing under the floor, the base would be supported with
wood framing (not shown) above the floor (not shown) and spacer 34
would be fixed to the base 12, with the upper edge 102 resting in
the lower edge 104 of the base, as shown in FIG. 5. An internally
threaded fitting (not shown) would then be screwed onto the
drainpipe 32 to form a permanent connection and the base 12 and the
drain lines.
[0034] The first wall section 14 is placed over the back edge of
the shower base 12, as shown in FIGS. 3 and 6 and against two walls
of the recreational vehicle (only wall 106 is shown in FIGS. 4 and
7). The upper edge of the first wall section 14 is attached to the
back wall 106 of the recreational vehicle using fastener 100 as
shown in FIGS. 4 and 7. Wall section 16 is positioned on top of
wall section 14, with the lower edge of wall section 16
interfitting with the upper edge of first wall section 14 as shown
in FIGS. 4 and 7. The upper edge 90 of wall section 16 is attached
to the recreational vehicle's wall surfaces in the same manner as
lower section 14 using attachment tabs 80, 82. Finally the third
wall section 18 is positioned on top of the second wall section 16
in the same manner and the top edge fastened to the recreational
vehicle wall surface using barbed plugs that extend through the
upper edge 96 of section 18 into the recreational vehicle walls
holding section 18 in position.
[0035] The individual sections are formed by injection molding. A
wide variety of different polymers can be used, such as
polyethylene, polypropylene, polyvinyl chloride and the like. Since
the wall sections are formed as one piece, with additional sections
stacked on top, the possibility of water leakage is minimized.
Caulking is not required and due to the flexibility of the
polymers, the installed shower stall can withstand the vibrations
typically encountered with a recreational vehicle. Also, due to the
interfitting construction, the shower stall can be installed very
quickly and easily.
[0036] As shown in FIGS. 9-20, features of the present invention
can also be incorporated into a bathtub 110 used in a recreational
vehicle. The tub 110 includes a floor or base 112, sidewalls 114
and a peripheral ledge 116. The base 112 incorporates an integral
drainpipe 120, which includes external threading 122. The bottom
surface of tub 110 includes ribbing 124 to provide further
support.
[0037] The tub 110 further includes a side edge lip 126, shown more
particularly in FIGS. 13 and 16, and a side panel or skirt 128,
which has an upper edge 130 that fits within a lower channel 132 of
edge 126.
[0038] The tub 110 includes a first outer flange 134 that runs
continuously along two sides and the back of the tub, and a
continuous first inner flange 136 which runs parallel to continuous
flange 134. In this instance, outer refers to away from the center
of the tub and inner refers to nearer the center of the tub. These
are adapted to receive three sidewall panels 138, 140 and 142.
Second side panel, or rear side panel 140 includes first and second
vertical side edges 144, 146. As shown in FIG. 19, each of these
side edges includes a vertical flange 148, which includes a
plurality of inwardly extended barbs 150. Sidewalls 138 and 142
each have vertical inner edges 152 adapted to mate with the
vertical flanges 148 of wall 140. Each vertical edge 152 includes a
channel 154 and a plurality of slots 156 adapted to receive the
barbs 150. Panels 138 and 142 also include outer vertical side
edges 162. Each side edge 162 includes a channel 164 adapted to
receive a barbed flange 167 of a trim piece 168, as shown in FIG.
19.
[0039] The tub enclosure also includes three upper walls 170, 172
and 174. These are identical to walls 138, 140 and 142. As shown in
FIG. 15, the bottom edge 200 of top panel 170 has a channel which
receives an upper portion 184 of panel 138 with a back edge of
panel 170 resting on ledge 186 of lower panel 138.
[0040] The tub enclosure of the present invention is installed by
positioning the tub in a desired location surrounded by three
adjoining walls of the recreational vehicle (not shown). A
drainpipe is connected to the preformed threaded drain 120 and
connected to the drainage system for the recreational vehicle. The
three panel walls 138, 140 and 142 are then snapped together, as
shown in FIGS. 10 and 19. The walls are then positioned in place
over the tub (FIG. 11), with the lower edges of the walls 188, 190,
192 that fit over continuous flanges 134, 136 of tub 110 in
position as shown in FIG. 14. The panels are held to the wall by
adhesive or barbed fasteners. This is then repeated with upper
walls 170, 172 and 174, with the lower edges 200, 202, 204 of the
walls 170, 172 and 174 resting on the upper edges 194, 196, 198 of
the walls 138, 140, 142. Finally, trim pieces 168 are positioned
along the side edges of panels 138, 170, 142 and 174 to finish the
side edges.
[0041] The panels themselves are all formed from injection molded
plastic, as is the tub itself, with the integral externally
threaded drainpipe. Thus, it is much less likely that the drainpipe
will become loose and leak because it is molded in place and
threaded onto the drain system of the recreational vehicle.
Further, the injection molded plastic walls provide a continuous
water barrier around three walls of the tub, preventing water from
getting behind the panels to the walls of the recreational vehicle.
Also, since the upper and lower walls are identical to each other,
fewer molds are required and the individual molds themselves are
smaller, further reducing costs. This also facilitates the easy
installation of the tub enclosure with minimal labor.
[0042] This has been a description of the present invention, along
with the preferred method of practicing the present invention,
however, the invention itself should only be defined by the
appended claims wherein I CLAIM:
* * * * *