Note: Descriptions are shown in the official language in which they were submitted.
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SHOWER ENCLOSURE
This invention relates to a shower enclosure and particularly but
not exclusively to a modular tub, tub surround and shower enclosure which is
formed in three separate pieces, separated by horizontal joints, the invention
being directed particularly to the lap joint formed between the parts of the
shower enclosure.
This application is an improvement on the arrangement shown in
our prior application Serial No. 2,110,629 filed December 3rd, 1993 in which
is
claimed and described many of the features described herein.
It is well known in the manufacture of bathroom fittings to
manufacture a modular tub/shower unit which includes a tub portion at the
bottom, a rear wall which is integral with the tub portion and extends
upwardly
therefrom and two side walls which are again integral with the tub portion and
extend upwardly therefrom at each end of the tub. At the top of the rear and
side walls is provided a top wall again as an integral construction. This
allows
the whole structure to be inserted into the cavity of a wall to form a
completely
waterproof surround into which a bather can step to use the tub or to shower
with the water falling into the tub. The fully enclosed waterproof structure
is
highly advantageous in that it prevents the escape of water into the wall
cavity
despite the shower spraying water onto the surrounding walls.
In initial installation of such a modular tub/shower arrangement in
a new building, the modular unit can be brought into place at an early stage
in
the construction of the walls so that it is possible to maneuver the
relatively
large and cumbersome structure through the building without dismantling
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doors, walls, or the like. However in a renovation project, often the walls,
doors, stairways and the like are already constructed and it is difficult to
the
transport the modular unit as a single construction through the building to
the
required location.
It has become accepted, therefore, that manufacturers of this type
of construction will manufacture both the single piece unit for a new
installation and a three piece unit which is manufactured for renovation
projects. The three piece unit is divided by horizontal joint lines to form a
top
piece which includes a top wall, the rear wall and two side walls; a center
piece which simply includes the rear wall and two side walls; and a bottom
piece which includes the tub structure and a small portion of the rear and
side
walls. Generally, the center piece is of greater height than the top and
bottom
pieces since this piece is more maneuverable.
One problem which has always arisen with products of this type is
that of forming a suitable joint between the top, middle and bottom pieces.
Various different styles of joint have been used including butt joints and lap
joints although in many cases additional connecting elements are positioned
rearwardly of the wall to clamp the wall pieces together; but these are
disadvantageous in that it is necessary to access these rear coupling
elements.
One example of a lap joint of this type is shown in U.S. patent
4,578,832 (Primucci) which includes a lap joint section with an upper part
diverted outwardly to engage over the lower part. An additional coupling
element is positioned between the parts to help maintain them attached.
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-3-
Fastening blocks are mounted on the outside surface to assist in clamping the
pieces together.
A further example is shown in U.S. patent 4,080,710 (Hess). This
discloses effectively a butt joint in which the lower part includes a rear leg
which is turned upwardly behind the butt joint to prevent the escape of
moisture. Two flanges at the butt joint are then clamped together by
fasteners.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide an improved
joint system for a modular tub/shower of the above type.
According to the invention there is provided a shower enclosure
comprising a wall assembly including a rear wall and at least one side wall,
said
wall assembly being divided at a horizontal joint into an upper wall part and
a
lower wall part for separate transportation into an installation location and
for
subsequent connection together at the horizontal joint to form the complete
wall assembly, each of the upper wall part and the lower wall part including a
respective portion of the rear wall and of the at least one side wall, the
wall
assembly having an inner surface facing inwardly and forwardly and an outer
surface facing outwardly and rearwardly, the lower wall part having an upper
most edge at the horizontal joint and the upper wall having a lowermost edge
at the horizontal joint, lap joint means defining a lap joint between the
upper
wall part and the lower wall part at the horizontal joint including limit
means for
limiting vertical movement of the wall parts toward one another to a
predetermined extent of overlap thereof, and a spring clip arrangement for
holding the upper wall part and the lower wall part in the lap joint
comprising a
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first clip member mounted on the outer surface of one of the upper and lower
wall parts and a second clip member mounted on the outer surface of the other
of the upper and lower wall parts, the first clip member defining an abutment
projecting outwardly of the wall parts, the second clip member having a hook
portion shaped to pass over the abutment as the wall parts are moved
vertically
toward one another and to engage over the abutment when the wall parts
reach said limit means to hold the wall parts against movement vertically
apart.
One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is an isometric view of an assembled modular tub/shower
unit of the type shown in the above prior application.
Figure 2 is a cross-sectional view through one portion of the initial
structure of the tub/shower unit prior to formation of the joint.
Figure 3 is a similar cross-sectional view as that of Figure 2
showing a next step in the formation of the joint.
Figure 4 is a yet further cross-sectional view similar to that of
Figure 2 showing a third step in the formation of the joint.
Figure 5 is a cross-sectional view similar to that of Figure 2
showing the finished joint.
Figure 6 is a cross-sectional view similar to that of Figure 5
showing the additional spring clip arrangement of the present invention for
snapping the joint into place and for applying pressure to the adhesive tape.
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In the drawings like characters of reference indicate corresponding
parts in the different figures.
DETAILED DESCRIPTION
A modular tub/shower unit is shown in Figure 1 and comprises
generally a top part 10, a center part 11 and a bottom part 12. The completed
unit includes a bottom tub section 13 together with a rear wall 14, a first
side
wall 15 and a second side wall 16. At the top part is also a top wall 17. In
the completely assembled unit, the tub and walls are effectively integral so
as
to prevent the escape of water around the tub and between the walls.
However for the manufacture of a renovation project, the
tub/shower unit is manufactured in the three separate pieces 10, 11 and 12
connected together at joint lines 18 and 19.
In the examples shown, the tub/shower unit is manufactured from
an acrylic material 20 which forms an inside layer and this is covered on the
outside by a mat 21 of a glass fiber reinforced resin material in conventional
manner. The technique for manufacturing includes initially the vacuum forming
the acrylic layer to form a substantially rigid structure of the required
shape
following which the acrylic layer is reinforced by the application onto the
outside surface of the resin and chopped fibers to form the glass fiber
reinforcement.
These techniques of manufacture and the general construction of
the modular tub/shower unit are well known, the improvement of the present
invention relating to the construction of the joint which is shown
schematically
in Figure 1 but is shown in more detail in Figures 2 through 5.
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Referring firstly to the finished joint structure shown in Figure 5,
the joint includes an upper wall part generally indicated at 30 and a lower
wall
part generally indicated at 31. It will be appreciated that the joints 18 and
19
are effectively identical so the joint shown in Figure 5 constitutes one of
those
joints. The wall parts 30 and 31 and therefore are simply generically shown
for
purposes only of describing the joint.
The upper wall part 30 includes a lowermost edge 32 and the
lower wall part 31 includes an uppermost edge 33. At a positioned spaced
from the lowermost edge 32, the upper wall part includes a recessed horizontal
band 34 including a base 35, an upper edge 36 and a lower edge 37. The
recess is formed in both the inner layer 20 and the rear or outer reinforcing
layer and has a depth approximately equal to the total depth of those two
layers. The recessed band thus forms a hollow recess on the inner surface and
a rib on the outer surface.
Between the lower edge 37 of the recessed band and the
lowermost edge 32 is provided a first horizontal band 38 which in the example
shown has a vertical height substantially equal to that of the base of the
recess
34. The inside surface of the first horizontal band 38 lies in a common
vertical
plane with the main portion of the upper wall part 30 so that the recess is
recessed from that common vertical plane indicated at 40. The lowermost
edge 32 is formed by a convex curved part 41 of the inner surface and is
defined by a portion of the inner layer 20 which is curved through 90°
so as to
terminate immediately adjacent the lower wall part 31.
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The lower wall part 31 includes a main wall portion 43 and a
second recessed band 44 which commences at a lower edge 45 and extends
therefrom upwardly to the uppermost edge 33. The vertical height of the band
44 is greater than that of the first horizontal band 38 by a distance
approximately equal to the vertical height of the recessed band 34. The
amount of the recess of the band 44 relative to the vertical surface of the
main
portion 43 is substantially equal to the amount of recess to the recessed band
34. The outside surface of the first band 38 and the outside surface of the
bottom edge 37 are both machined as indicated at 46, 47 to form flat surfaces
at right angles to accurately receive the inside surface of the band 44 and
the
uppermost edge 33. Between the outside surface of the band 38 and the
inside surface of the band 44 is provided a double sided adhesive tape 48
which bonds together those two surfaces in fixed position.
In the finished joint, the double sided adhesive tape constitutes the
only sealing means to prevent the escape of moisture. Thus there is no need
for additional silicone or similar type sealant beads to be added since
moisture
will tend to run down the upper wall part and is limited in its ability to
move
upwardly through the lap joint and is prevented from passing through that lap
joint by the strong adhesive effect provided by the double sided adhesive
tape.
In addition the double sided adhesive tape and the interconnection
at the lap joint constitute the only structural members providing the
interconnection at the joint. Thus there is no necessity for additional
coupling
blocks or clamping elements which are located outside the structure, although
these can be provided if desired for increased structural stability.
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The recessed band 34 provides an upper edge 36 which allows a
user to grasp the upper wall part and lift the upper wall part. The lower edge
37 similarly allows vertical downward force to be applied to the upper part to
bring it into a position in which the machined surfaces 46 and 47 are properly
in position against the abutting surfaces of the lower wall part 31. In
addition
the recessed band 34 provides a stiffening effect at the joint. Furthermore
the
lower edge 37 provides a stop member locating the uppermost edge 33.
The recessed band 44 similarly provides a stiffening effect at the
upper edge of the lower wall part. In addition the space between the
lowermost edge 32 and the lower edge 45 of the recessed band provides an
attractive appearance in that it matches the recessed band 34 thus providing
an appearance of a double groove as shown in Figure 1. This double groove
tends to remove from vision the actual joint line provided at the lowermost
edge 32.
This construction has the following advantages.
1. The unit can be installed and assembled in position without
access to the back side of the structure.
2. The groove or recess 34 provides a finger grip to enable the
user to assemble the sections from the inside.
3. The groove 34 stiffens or strengthens the walls at the joint line.
4. The lap joint system with the upper wall part providing the
inner wall ensures a leak proof joint line.
5. The use of the double sided tape provides both the sealing of
the joint line without additional sealant and provides the
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structural strength of the joint line without additional joining
elements.
The steps in manufacture of the joint are shown in Figures 2, 3,
and 4. In Figure 2 an initial construction is shown in which the bands 34 and
44 are formed by a molding technique with the addition of a further groove 50
positioned between these bands defining a U-shape section simply as a
connector piece to be removed.
In the next step, a cutting blade provides a cutting action along
the lines 51 and 52 so as to remove the U-shaped groove 50. It will be noted
that the cutting line 51 is positioned just below the curved wall part 41 so
as to
leave this outwardly curved inside layer portion in tact. The cut line 52 is
however positioned slightly lower so as to cut away the outwardly curved
portion at that cut line thus forming a directly horizontal blunt cut end at
the
uppermost edge 33.
After the cutting is complete, a machine tool in the form of a
router is applied to the surfaces 46 and 47 to provide the direct right angle
straight line surfaces necessary for engagement with the surfaces of the lower
wall part.
The next step requires the application of the double sided adhesive
tape 47 which is covered by a covering layer 53 on the surface away from the
surface 47. The upper wall part can thus be assembled in engagement with
the lower wall part for transportation or storage purposes without the
adhesive
causing a permanent bond.
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The next stage in the assembly process is the final installation at
the required location at which time the upper wall part and lower wall part
are
properly assembled after transportation to the necessary location. The user
can grasp the upper wall part at the groove or recess 34 to provide upward or
downward pressure to move the elements relative to one another to bring the
uppermost edge 33 properly into engagement with the surface 46. At this
point, one part of the covering layer 53 can be grasped and pulled so it is
pulled away from its engagement with the outside surface of the tape 48. As
shown in Figure 4, slight pressure indicated by the arrow 55 at the point of
pulling on the tape 53 as indicated at the arrow 56 will cause the lower wall
part to distort slightly rearwardly to provide enough of a gap between the
upper and lower wall part for the tape or covering layer 53 to be extracted.
Once extracted, pressure on the band 38 as indicated at the arrow 57 will
cause a final bonding between the adhesive tape and the inside surface of the
band 44.
Turning now to Figure 6 there is shown the arrangement of the
present invention in which there is provided an additional spring clip
arrangement which assists in the assembly of the joint and may in addition
provide structural stability after the joint is assembled. Although only one
such
spring clip arrangement is shown in Figure 6. It will be appreciated that
there
are a number of such spring clips arranged at spaced positions along the
length
of each joint.
Each spring clip arrangement therefore comprises a first clip
member 60 and a second clip member 61 which cooperate at the joint fine. A
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. . _ 11 _
wooden block 62 is attached to the upper wall part immediately above the
upper edge of the recessed band 34 with an outer surface 63 of the wooden
block substantially co-planar with the outer surface of the recess band 34. A
similar wooden block 64 is attached to the lower wall part immediately
underneath the recess section 45. Again the wooden block 64 has an outer
surface 65 co-planar with the outer surface of the second band portion 44.
The spring clip member 60 includes a first portion 66 attached to
the outer surface 63. From the bottom edge of the block 62, the spring clip
member 60 includes a second portion 67 which is inclined downwardly and
outwardly to a position beyond the joint line. At the lowermost end of the
second or spring band portion 67 there is provided a portion 68 which is
turned
inwardly from the lowermost end 69 of the spring band portion 67.
The clip member 61 includes a first portion 70 lying flat against
the outward surface 65 of the block 64 and against the outer surface of the
second band portion 44. At a position just below the joint line that is the
top
edge 33 of the lower wall part, the second spring clip member 61 turns
downwardly and outwardly to form a second portion 72 having a lower
abutment end 73 spaced downwardly from the upper edge 33.
Prior to assembly of the upper and lower wall parts, the first
spring member 60 is spaced upwardly above the second spring clip member 61
so that the hook portion 68 is above the abutment portion 72. When the upper
wall part is pulled downwardly onto the lower wall part, an inner end 74 of
the
hook portion 68 engages the outer surface of the abutment portion 72 and
slides over that outer surface until the hook portion 68 passes beyond the
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abutment end 73. The location of the spring clip members on the upper and
lower wall parts is arranged so that the hook portion 68 passes over the
abutment end 73 only when the upper wall part is fully pulled down. onto the
limit of the lower wall part defined by the upper edge 33. Thus when the parts
are fully pulled together in the vertical direction, the hook portion 68 snaps
over the abutment end 73 to hold the upper and lower wall parts together to
prevent vertical movement apart. In addition the snap sound caused by the
hook portion 68 engaging over the abutment end indicates to the installer (who
cannot see the spring clip members) that the upper wall part has been fully
pulled down to its position in the lower wall part.
In addition to the location of the parts in the vertical direction, the
spring band portion 67 is spring biased in a direction toward the outer
surface
of the wall parts so as to provide a pushing force on the abutment end 73
tending to push the upper band 44 of the lower wall part inwardly. At the
same time the upper end of the spring band 67 pulls the lower edge of the
upper wall rearwardly thus squeezing the adhesive tape to further improve the
curing action of the tape in bonding to the inner surface of the band 44.
Since various modifications can be made in our invention as
hereinabove described, and many apparently widely different embodiments of
same made within the spirit and scope of the claims without departing from
such spirit and scope, it is intended that all matter contained in the
accompanying specification shall be interpreted as illustrative only and not
in a
limiting sense.
