Patent Application
20050086736
The present invention relates to an interface between panels of a molded plastic shower surround and a method of assembly therefor.
Conventional modular tub/shower units often include a base portion at the bottom and two or more wall portions. The whole structure is mounted adjacent a wall or corner to form a waterproof surround. The fully enclosed waterproof structure is highly advantageous in that it prevents the escape of water into the wall structure despite the shower spraying water onto the surrounding walls.
One problem which arises with products of this type is that of an uncomplicated assembly which will form a suitable joint between the surround portions. Various styles of joint have been used, each of which provide particular tradeoffs in complexity, aesthetics, and sealing ability.
Accordingly, it is desirable to provide a waterproof assembly interface between wall portions of a molded plastic shower surround which is uncomplicated and aesthetically pleasing while assuring an effective watertight seal.
The molded shower surround according to the present invention includes a base portion which receives wall portions and a corner portion therebetween. The base portion is located in a corner between two walls. The wall portions are located upon a ledge defined by the base portion. A corner slot is located within the ledge to receive a corner tab which extends from a lower end of the corner portion.
The corner portion includes an upper lock tab and a lower lock tab adjacent the outer edges. An upper lock slot and a lower lock slot are located adjacent the inner edge of each wall portion which engage the corner portion. Each side of the corner portion includes a corner flange arranged substantially perpendicular to a corner planar surface. Each of the corner planar surfaces are substantially parallel to the wall portions when in a mounted position. The corner flange is received within a molded slot which extends along the vertical length of the wall portion to provide an aesthetically pleasing interface. The corner flange and the molded slots when combined with the upper lock tab and the lower lock tab, which respectively engage the upper lock slot and the lower lock slot, provide a watertight interlocking arrangement between the corner portion and the wall portions.
In one assembly method, the base portion is positioned. The wall portions are then assembled to the corner portion. The three connected sections are then fitted to the base portion such that the corner portion is aligned such that the corner flanges are located within the molded slots. The corner portion is then slid downward until the corner tab enters the corner slot and the portions are locked to the base portion.
In another assembly method the base portion is initially not position or fastened to the wall. The corner and wall portions are assembled to the base portion such that the assembled shower assembly can be “slid” into the corner.
The present invention therefore provides a waterproof assembly interface between wall portions of a molded plastic shower surround which is uncomplicated and aesthetically pleasing while assuring an effective watertight seal.
The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
Referring to
The base portion 28 defines a floor 34 bounded by a raised ledge 36. The ledge 36 of the base portion 22 preferably includes a first side 32a located perpendicular to a second side 32b. The hypotenuse side 32c of the base portion is preferably arcuate and includes a relief 33 in which a shower door (not shown) is located. A base periphery flange 38a, 38b preferably extend from the sides 32a, 32b to receive fasteners 40 such as nails which pass through the flanges 38a, 38b and into the vertical wooden studs Sv.
Referring to
A corner slot 42 is located within the ledge 36 where the sides 32a, 32b meet. A corner tab 44 which extends from a lower end of the corner portion 28 fits into the corner slot 42 (
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The upper lock slot 52 is located within a raised area 56 which extends from a planar portion 58 of each wall portion 24, 26. The planar portion 58 generally includes the flange 24f, 26f. The raised area 56 extends toward the interior of the shower surround 20 (
The lower lock slot 54 includes a lock slot tab 60 which extends inward of the raised area 56. That is, the upper lock slot tab 60 extends toward the interior of the shower surround 20 to engage the vertical portion 48v of the lower lock tab 48 (
Referring to
The corner flange 62 and the molded slot 66, when combined with the upper lock tab 46 and the lower lock tab 48 (
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Preferably, glass groove 70 includes an aperture to receive a fastener 74 such as a screw. The fastener 74 passes through the glass groove 70 and engages into the wall W1 and vertical stud Sv. The fastener 74 is enclosed by the side glass panel 68a which fits into the glass groove 70 preferably through a sealant-less joint. That is, the flexibility of the glass groove 70 provides for an interference fit with the side glass panel 68a which minimizes or eliminates the need for caulk.
In one assembly method, the base portion 22 is mounted to a wall of a structure. Preferably, the base portion 22 is located in a corner. The wall portions 24, 26 are then assembled to the corner portion 28. The three connected sections 24, 26, 28 are then fitted to the base portion 22 such that the corner portion 28 is aligned and the corner flanges are located within the molded slots. The corner portion 28 is then aligned such that the corner flanges 62 are located within the molded slots 66 and the portions 24, 26, 28 are locked to the base portion 22. Preferably, the corner portion and a wall portion 24, 26 is locked into a sub-assembly then this sub-assembly is lifted and slide onto to the second wall which may already be mounted to the base portion 22. Each edge trim portion 27a, 27b is then mounted to the wall portions 24, 26 and the glass enclosure 68 without the need for caulk.
In another assembly method the base portion 22 is initially not position or fastened to the structure such as a corner or wall. The corner portion 28 and wall portions 24, 26 are assembled to the base portion 22 such that the assembled shower assembly can be “slid” into the corner.
It should be understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude of the vehicle and should not be considered otherwise limiting.
The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.
