BACKGROUND AND SUMMARY OF THE DISCLOSURE
The present disclosure relates generally to a shower wall system and, more particularly, to a shower wall system including a wall supported shower seat.
Conventional shower or bathing wall systems may include seats for supporting a user. However, such seats are often difficult to install and may require relatively complex support structures that do not facilitate retrofitting to existing shower installations. As such, there is a need for a bathing wall system including a shower seat supported by an individual wall panel and secured to studs and/or stringers of an existing support wall.
The present disclosure provides for a bathing wall system including a wall supported shower seat allowing it to be paired with a separate shower base, as opposed to being molded into the shower base itself. This provides for flexibility and ease of installation, particularly with multi-piece bathing fixtures used in remodel applications.
The illustrative shower seat of the present disclosure is molded into an end wall panel, such that loads on the seat are transferred to a stud wall without requiring support from, or resting on, the shower base. The seat is essentially cantilevered over the shower base.
The illustrative bathing wall system includes a coupler to structurally connect the seat panel assembly to an installation pocket wall. The coupler includes a horizontal bracket mounted to the pocket wall (typically a wood stud). The illustrative seat panel assembly includes a thermoformed outer shell, and an internal molded high-density foam core with hangers coupled thereto that protrude out a rear of the assembly. The seat hangers hook onto the wall-mounted bracket. This allows the seat assembly to be suspended in a cantilevered fashion onto the pocket wall via the bracket.
According to an illustrative embodiment of the present disclosure, a bathing wall system includes a back wall panel extending between a first side edge and an opposing second side edge, and an end wall panel including a rear edge operably coupled to one of the first side edge and a second side edge of the back wall panel. The end wall panel includes an integral shower seat. A coupler secures the end wall panel to a support wall. The coupler includes a bracket secured to the support wall, and a hanger secured to the end wall panel and suspended from the bracket.
According to another illustrative embodiment of the present disclosure, a bathing wall system includes an upper wall section, and a lower wall section positioned below the upper wall section. The upper wall section includes an upper back wall panel and an upper end wall panel. The lower wall section includes a lower back wall panel and a lower end wall panel. A cantilevered shower seat is integrally formed with at least one of the lower back wall panel and the lower end wall panel.
According to a further illustrative embodiment of the present disclosure, a shower wall panel includes an outer shell having a peripheral portion and an inner portion extending inwardly from the peripheral portion to define a pocket. The inner core is received within the pocket of the outer shell. The inner portion of the outer shell and the inner core define a cantilevered shower seat.
According to another illustrative embodiment of the present disclosure, a shower wall panel includes a cantilevered shower seat, and a coupler including a bracket and a hanger. The bracket is secured to a support wall, and the hanger is secured to the shower seat and suspended from the bracket. The hanger is slidably supported by the bracket.
Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the intended advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description of exemplary embodiments when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a right front perspective view of an illustrative bathing wall system in accordance with the present disclosure;
FIG. 2 is a left front perspective view of the illustrative bathing wall system of FIG. 1;
FIG. 3 is a front elevational view of the illustrative bathing wall system of FIG. 1;
FIG. 4 is a partially exploded perspective view of the illustrative bathing wall system of FIG. 1;
FIG. 5 is a further exploded perspective view of the illustrative bathing wall system of FIG. 1;
FIG. 6 is a perspective view showing the mounting of a right end wall panel to a support structure;
FIG. 7 is a rear elevational view of the right end wall panel of FIG. 6;
FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 6;
FIG. 9 is a detail view of the coupler of FIG. 8;
FIG. 10 is a cross-sectional view taken along line 10-10 of FIG. 6;
FIG. 11 is a cross-sectional view taken along line 11-11 of FIG. 6;
FIG. 12 is a perspective view showing the coupler of the bathing wall system of FIG. 1;
FIG. 13 is an exploded perspective view of the lower wall section of the bathing wall system of FIG. 1;
FIG. 14 is a perspective view of a connection between the lower back wall panel and the lower right end wall panel of the bathing wall system of FIG. 1;
FIG. 15A is a cross-sectional view taken along line 15A-15A of FIG. 14;
FIG. 15B is a cross-sectional view taken along line 15B-15B of FIG. 14;
FIG. 16A is an exploded top plan view of the connection of FIG. 14;
FIG. 16B is an exploded perspective view of the connection of FIG. 16A;
FIG. 17 is a perspective view of the right end wall panel of FIG. 13;
FIG. 18 is an exploded perspective view of the right end wall panel of FIG. 13;
FIG. 19 is a partially exploded perspective view of the seat of FIG. 13;
FIG. 20 is a further exploded perspective view of the seat of FIG. 19;
FIG. 21 is a partial bottom perspective view of the seat of FIG. 19; and
FIG. 22 is a perspective view of the illustrative coupler of FIG. 21, shown secured to a support wall.
Corresponding reference characters indicate corresponding parts throughout the several view. Although the drawings represent exemplary embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate exemplary embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE DRAWINGS
For the purposes of promoting and understanding the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein. The embodiments disclosed herein are not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the claimed invention is thereby intended. The present invention includes any alterations and further modifications of the illustrated devices and described methods and further applications of principles in the invention which would normally occur to one skilled in the art to which the invention relates.
Referring initially to FIGS. 1-5, an illustrative bathing wall system 10 of the present disclosure is shown as including a base 12, a lower wall section 14 supported above the base 12, and an upper wall section 16 supported above the lower wall section 14. The base 12 may be of conventional design and is illustratively formed of a thermoformed acrylic or a porcelain enameled steel. The illustrative base 12 includes an upper surface 18, and peripheral edges 20 extending upwardly from the upper surface 18. The upper surface 18 illustratively defines a drain opening 22 and is supported by a subfloor 24 (FIG. 1).
The lower wall section 14 illustratively includes a lower back wall panel 26 operably coupled to a lower left end wall panel 28 and to a lower right end wall panel 30. The upper wall section 16 illustratively includes an upper back wall panel 32 operably coupled to an upper left end wall panel 34 and to an upper right end wall panel 36. In other illustrative embodiments, the upper wall section 16 may be formed of other conventional components (e.g., ceramic tile) or eliminated in its entirety. In certain illustrative embodiments, the upper wall section 16 may be combined with the lower wall section 14.
The back wall panels 26, 32 and the end wall panels 28, 30, 34, 36 illustratively form an open enclosure 40, within which a user can shower and/or bathe. It should be appreciated that the dimensions, number and arrangement of the wall panels 26, 28, 30 and 32, 34, 36 may vary.
FIGS. 1 and 6 illustrate a portion of a conventional support wall 42 extending upwardly from the subfloor 24. The support wall 42 illustratively includes vertical studs 44 and a horizontal stringer 46 extending between at least two of the studs 44. The studs 44 and the stringers 46 may be formed of a conventional material, such as wood. As further detailed herein, the lower wall section 14 and the upper wall section 16 may be secured to the support wall 42.
The wall panels 26, 28, 30, 32, 34, 36 may be formed of a conventional material, such as a polymer. In one illustrative embodiment, the wall panels 26, 28, 30, 32, 34, 36 are formed of a thermoformable material, such as a thermoformed acrylic. As further detailed herein, the wall panels 26, 28, 30 of the lower wall section 14 and the wall panels 32, 34, 36 of the upper wall section 16 are illustratively configured to fit together in such a way that provides a watertight seal without the use of caulk, gaskets, weather stripping, or other conventional sealants.
With reference to FIGS. 1-3, a bottom of the lower back wall panel 26 is supported above the base 12 defining a lower drainage opening or gap 47. The illustrative lower wall section 14 includes joints or connections 48 and 50 operably coupling together the wall panels 26, 28 and the wall panels 26, 30, respectively. More particularly, opposing right and left sides 52 and 54 of back wall panel 26 are connected to the left and right end wall panels 28 and 30 at left and right corner joints or connections 48 and 50, respectively (FIG. 5). The end wall panels 28 and 30 are also supported above the base 12 to define right and left lower drainage openings or gaps 56 and 58. Each end wall panel 28 and 30 includes a rear or inner side 60 and 62 coupled to back wall panel 26 at corner joints or connections 48 and 50, and a front or outer side 64 and 66 facing an open end 68 of the base 12 (FIGS. 1, 2 and 5).
As further shown in FIGS. 1-5, the lower back wall panel 26 of the bathing wall system 10 may illustratively include molded aesthetic and ergonomic features such as a shelf 72. In some illustrative embodiments, the lower back wall panel 26 may have other molded features known in the art (e.g., cavities), or the features may be configured in other ways. With reference to FIG. 5, illustrative lower back wall panel 26 may also include a dry wall lip or mounting flange 76, a first coupling or snap-mount portion 78, and bottom standoffs or splines 80. Dry wall lip 76 extends horizontally across the top edge of back wall panel 26. As further detailed herein, the lip 76 of the back wall panel 26 may be secured to studs 44 of the support wall 42 via screws (not shown) extending through the lip 76.
First coupling or snap-mount portions 78 of each joint 48 and 50 illustratively extend vertically down both sides of, and span the height of, the lower back wall panel 26. Bottom splines 80 are raised portions which extend in spaced apart relationship horizontally across the bottom edge of the lower back wall panel 26. The bottom splines 80 and are configured to allow water to flow from underneath the lower back wall panel 26 through the drainage opening 47, and into the base 12.
As further detailed in FIGS. 5 and 14-16B, each snap-mount portion 78 of the lower back wall panel 26 includes a U-shaped channel 82, a snap flange 84, and protrusions 86. The U-shaped channel 82 is defined by a terminal side end or edge 88 of the lower back wall panel 26, an outward extension 90 from the terminal side end 88, and snap flange 84. Snap flange 84 is a thin forward extension which spans a distance less than the depth of U-shaped channel 82. Protrusions 86 extend horizontally outward from a plane defined by the lower back wall panel 26, to a length less than that of U-shaped channel 82. The protrusions 86 illustratively extend from a forwardmost end of the terminal side end 88 of the back wall 14. Illustrative protrusions 86 have a depth also less than that of U-shaped channel 82 and are defined by a rounded edge, illustratively a forward or convex curve 93. As shown in FIG. 16B, multiple protrusions 86 are illustratively spaced apart in a vertical direction along the side edge 88 of back wall panel 26. Snap-mount portion 78 disposed on the opposite side of back wall panel 26 illustratively includes the same shape and structure as depicted in FIGS. 14-16B.
As shown in FIGS. 15B-16B, an upper flange 94 is positioned above and outwardly from the snap flange 84. As further detailed herein, the upper flange 94 defines a water channeling feature.
As further shown in FIGS. 1-5, the lower end wall panels 28 and 30 may also include aesthetic and ergonomic features similar to the lower back wall panel 26. In some illustrative embodiments, end wall panels 28 and 30 may have different functional and/or aesthetic features from each other, and may include additional shelves, different sized cavities, etc. In other illustrative embodiments, the lower end wall panels 28 and 30 may have identical functional and/or aesthetic features and be mirror images of each other. The lower end wall panels 28 and 30 illustratively also include dry wall lips or mounting flanges 95 and 96, bottom standoffs or splines 98, and a second coupling or snap-mount portion 100 (e.g., snap groove connector).
With further reference to FIGS. 4 and 5, dry wall lip or mounting flange 95 extends horizontally across the top edge of end wall panels 28 and 30, and dry wall lip or mounting flange 96 extends vertically along the outer side edge of the lower end wall panels 28 and 30. As further detailed herein, the lips 94 and 96 of the respective end wall panels 28 and 30 may be secured to studs 44 of the support wall 42 via screws (not shown) extending through the lips 94 and 96. Bottom splines 98 are raised portions which extend in spaced apart relationship horizontally across the bottom edge 102 of end wall panel 28, 30 and are configured to allow water to flow from underneath the respective end wall panel 28, 30, via the drainage openings 56 and 58, respectively, and into the base 12.
Referring again to FIGS. 5 and 14-16B, second coupling portion 100 is disposed along the rear side 104 of each lower end wall panel 28 and 30. As detailed in FIGS. 14-16B, second coupling portion 100 of each end wall panel 28 and 30 includes a snap groove 106, a positive pressure bead 108, and a groove connector 110. Snap groove 106 extends vertically down the side 104 of each end wall panel 28 and 30. Pressure beads 108 are raised pyramid shapes with rounded edges and, as best shown in FIG. 5, are spaced apart in a vertical direction along the length of snap-mount portion 100. As shown in FIGS. 15A and 15B, pressure beads 108 extend approximately the width of U-shaped channel 82 and are configured to engage snap flange 84 when the lower back wall panel 26 and respective lower end wall panels 28, 30 are mounted together.
An upper flange 112 of the lower right end wall panel 30 is illustratively received within the upper flange 94 of the lower back wall panel 26. Illustratively, the flanges 94 and 112 define a water channel 114.
Illustrative joints or connections 48 and 50 between wall panels 26, 28, 30 of the lower wall section 14 may be of the type further detailed in U.S. Pat. No. 11,700,974 to Ferris et al., the disclosure of which is expressly incorporated herein by reference.
With reference to FIGS. 1-5 and 17-20, the lower right end wall panel 30 illustratively includes a cantilevered seat 120 supported above, and in spaced relation to, the base 12. More particularly, a gap 122 extends between the upper surface 18 of the base 12 and the seat 120 (FIG. 3). The seat 120 may alternatively be formed in the lower back wall panel 26 and/or the lower left end wall panel 28 using a similar design. As such, while the following description details the lower right end wall panel 30, it should be appreciated that the lower back wall panel 26 and/or the lower left end wall panel 28 may include similar features.
With reference to FIGS. 6-13 and 17-20, the illustrative lower right end wall panel 30 includes an outer shell 124 receiving an inner seat core 126. The outer shell 124 illustratively includes a vertically extending outer or peripheral portion 127 and an inwardly extending portion 128 defining a chamber or pocket 130. The peripheral portion 127 includes a substantially planar surface 132 extending in a vertical direction. The inwardly extending portion 128 defines an upwardly facing support surface 134 of the seat 120. The support surface 134 is a substantially planar surface extending in a horizontal direction. The outer shell 124 is illustratively formed from a polymer, such as a thermoformed acrylic. In one illustrative embodiment, the outer shell 124 is formed from a high impact polyethylene.
The illustrative inner seat core 126 includes a mounting portion or flange 135 supporting an insert portion 140 received within the pocket 130 of the outer shell 124. The inner seat core 126 illustratively includes an upper seat portion 136 and a lower seat portion 138. The upper seat portion 136 and the lower seat portion 138 are both illustratively formed of a polymer, illustratively a high density expanded form. In one illustrative embodiment, the upper seat portion 136 and the lower seat portion 138 are formed of an expanded polypropylene (EPP) foam. A conventional adhesive may be placed intermediate a lower surface 139 of the upper seat portion 136 and an upper surface 141 of the lower seat portion 138 to help secure together the upper seat portion 136 and the lower seat portion 138 of the inner seat core 126 (FIGS. 18-20).
With reference to FIGS. 8 and 18-22, a coupler 142 illustratively secures the lower end wall panel 30 to the support wall 42. First and second support arms 144 and 146 are illustratively received intermediate the upper seat portion 132 and the lower seat portion 134. First or distal ends 148 of the support arms 144 and 146 are received within the inner seat core 126, while second or proximal ends 150 of the support arms 144 and 146 are secured to the coupler 142. Illustratively, the support arms 144 and 146 are U-shaped channels formed of a metal, such as stainless steel. The distal ends 148 of the channels of the support arms 144 and 146 are illustratively closed via an end wall 151 to facilitate retention within the inner seat core 126 (FIG. 22).
With reference to FIGS. 11 and 18-22, the first and second support arms 144 and 146 are illustratively received within locator protrusions or rails 152 and 154 defined by the lower seat portion 134. Each of the illustrative support arms 144 and 146 includes a plurality of spaced apart openings 156 extending between the respective first and second ends 148 and 150. Illustratively, a plurality of protrusions 158 extend upwardly from the lower seat portion 134 through the openings 156 in the support arms 144 and 146 and into receiving bores 160 in the upper seat portion 132. In certain illustrative embodiments, the plurality of protrusions 158 may include radially extending protrusions or crush ribs (not shown) to help retain the support arms 144 and 146 to the inner seat core 126.
With reference to FIGS. 6-9, 12, 13 and 17-22, the illustrative coupler 142 includes a mounting bracket 162 secured to the support wall 42, and hangers 164 and 166 secured to the lower end wall panel 30 and suspended from the bracket 162. The bracket 162 is illustratively formed of a metal, such as aluminum. As shown, the illustrative bracket 162 includes a mounting portion 168 and a laterally offset hanger support 170. The mounting portion 168 includes a plurality of spaced apart openings 172 to receive fasteners 174 to secure the bracket 162 to the support wall 42. More particularly, wood screws 174 may extend through the openings 172 to secure the bracket 162 to stringer 46. Illustratively, the openings 172 are elongated to facilitate lateral adjustment of the bracket 162.
The hangers 164 and 166 each illustratively include a hook 176 and a mounting plate 178. The support arms 144 and 146 are coupled to the hangers 164 and 166 illustratively via conventional fasteners 180, such as screws, received within openings 181 of the mounting plates 178. The openings 181 may be elongated slots to facilitate adjustment during assembly (FIG. 18). The mounting plates 178 are shown secured to lower surfaces of the support arms 144 and 146. However, for ease of assembly by providing access to the screws 180, the mounting plates 178 may be secured to other locations on the support arms 144 and 146, illustratively upper surfaces thereof. The hangers 164 and 166 may be slidably moved along the hanger support 170 of the mounting bracket 162, thereby facilitating lateral adjustment of the end wall panel 30, and thereby the seat 120. Illustratively, the hangers 164 and 166 are formed of a metal, such as aluminum.
As may be appreciated, the seat 120 is cantilevered above the base 12 by the end wall panel 30. A load on the support surface 134 of the seat 120 will generate a moment causing a reaction force on an outer lower edge 182 of the inner seat core 126. To assist in distributing the load against the studs 44 of the support wall 42 and to protect the inner seat core 126, a lower plate 184 is illustratively coupled to the lower edge 182 of the inner seat core 126. Illustratively, the lower plate 184 is an L-shaped channel formed of a metal (e.g., aluminum) and may be secured in place via a conventional adhesive.
Illustratively, the seat 120 and cooperating coupler 142 are configured to support a 500 pound user sitting on the support surface 134 (i.e., a static load).
With further reference to FIGS. 1-5, similar to the lower wall section 14, the illustrative upper wall section 16 includes joints or connections 188 and 190 operably coupling together the wall panels 32, 34, 36. More particularly, opposing right and left sides 192 and 194 of the upper back wall panel 32 are connected to the left and right end wall panels 34 and 36 at right and left corner joints or connections 188 and 190, respectively. Each upper end wall panel 34 and 36 includes a rear or inner side 196 and 198 coupled to back wall panel 32 at corner joints or connections 188 and 190, and a front or outer side 200 and 202 facing the open end 68 of the base 12.
With reference to FIGS. 1-5, the upper back wall panel 32 of the bathing wall system 10 may illustratively include molded aesthetic and ergonomic features such as a shelves 204 and cavities 206. In some illustrative embodiments, the lower back wall panel 32 may have other molded features known in the art, or the features may be configured in other ways. Illustrative lower back wall panel 32 may also include a dry wall lip or mounting flange 208, and a first coupling or snap-mount portion 210. Dry wall lip 208 extends horizontally across the top edge of back wall panel 32. Snap-mount portions 210 illustratively extend vertically down both sides of, and span the height of, the back wall panel 32.
The end wall panels 34 and 36 may also include aesthetic and ergonomic features similar to back wall panel 32. In some illustrative embodiments, end wall panels 34 and 36 may have different functional and/or aesthetic features from each other, and may include additional shelves, different sized cavities, etc. In other illustrative embodiments, end wall panels 34 and 36 may have identical functional and/or aesthetic features and be mirror images of each other. End wall panels 34 and 36 illustratively also include dry wall lips or mounting flanges 212 and 214, and a second coupling or snap-mount portion 216 (e.g., snap groove connector). With reference to FIGS. 4 and 5, dry wall lip or mounting flange 212 extends horizontally across the top edge of end wall panels 34 and 36, and dry wall lip or mounting flange 214 extends vertically along the side edge of the end wall panels 34 and 36.
Illustrative joints or connections 188 and 190 between wall panels 32, 34, 36 of the upper wall section 16 may be similar to the joints or connections 48 and 50 between wall panels 26, 28, 30 of the lower wall section 14. Moreover, the joints or connections 188 and 190 may be of the type further detailed in U.S. Pat. No. 11,700,974 to Ferris et al., the disclosure of which is expressly incorporated herein by reference.
Assembly of the illustrative bathing wall system 10 initially begins by installing the base 12 by securing it to the subfloor 24, illustratively via a conventional adhesive (e.g., glue or mortar). The mounting bracket 162 may then be secured to the stringer 46 of the support wall 42. Next, the lower back wall panel 26 is positioned and secured in place via screws extending though the mounting lip 76 into the studs 44 of the support wall 42.
The lower left wall panel 28 is then snap-fit via the connection 48 to the back wall panel 26 and may be secured in place with screws extending through the mounting lips 95 and 96. Next, the right end wall panel 30 may be secured in place by suspending the hangers 164 and 166 on to the mounting bracket 162 and simultaneously securing the right end wall panel 30 to the back wall panel 26 via the snap-fit connection 50. Again, the lower right end wall panel 30 may be further secured via screws extending through lips 95 and 96 into the studs 44 of the support wall 42.
Next, the upper wall section 16 may be installed above the lower wall section 14. The upper wall section 16 may be installed in a similar manner as the lower wall section 14. More particularly, the upper back wall panel 32 may be secured to the support wall 42 via screws extending through the mounting lip 32. Next, the left end wall panel 34 and the right end wall panel 36 are illustratively secured to the back wall panel 32 via the snap-fit connections 188 and 190, respectively. The left and right end wall panels 34 and 36 may be further secured via screws extending though lips 212 and 214 into the studs 44 of the support wall 42.
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.
Patent Application
20250160578
