Note: Descriptions are shown in the official language in which they were submitted.
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CA 02551357 2006-06-30
PROTECTIVE LINER
FIELD OF THE INVENTION
The present invention relates to a device and a method of protecting bathtubs
and shower
units, and in particular to protecting bathtubs and shower units during the
construction of a
building.
BACKGROUND OF THE INVENTION
During the framing stage of construction of a building it is common practice
to place
bathtubs and shower units (collectively referred to as 'bathing fixtures") in
the rooms that that
they will eventually be installed in. Consequently, such bathing fixtures are
exposed to a
substantia:l portion of the construction and finishing process. During
construction, bathing
fixtures are inadvertently subjected to a variety of physical abuses including
rain, dirty footwear,
rocks, nails, staples, screws, ladders, stilts, trowels, knives, dropped tiles
and general use as a
garbage receptacle. Such physical abuse frequently damages the exposed
surfaces of the bathing
fixtures manifesting itself in the form of stains, scratches, dents and chips.
Various types of cover have been used to try and protect bathing fixtures
during the
construction process. Many of the covers that have been tried are makeshift in
nature having
little effect, or even compounding the damage. Wooden and cardboard covers
have been used
but they tend to slide around on the surface of the bathing fixtures causing
scratches at the point
of contact. Further, trades people frequently discard such covers because the
cover physically
interferes with their tasks such as tiling, framing and plumbing. Paper based
covers are also of
limited utility as they tend to disintegrate if subjected to moisture.
Covers have been tried that incorporate attachment devices such as magnets and
suction
cups however, they have had limited success and are unduly complex to produce
and use.
Another suggested solution is the use of rigid vinyl or hard plastic liners.
Such liners are
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CA 02551357 2006-06-30
expensive and complicated to make and they are bulky to transport to the work
site. Another
problem is that such hard liners obstruct the subsequent plumbing of the
faucets and plug
assembly. As a result they are often removed and discarded by trade people. A
further problem
with rigid liners is their inability to absorb the impact of heavy objects
dropped on to the bathing
fixture resulting in damage to the underlying section of the bathing fixture.
Therefore, what is required is an inexpensive protective cover that does not
unduly
interfere with the ability of the trades people to complete their tasks, that
is tightly fitted to the
bathing fixture to stay in place and to prevent the entry of foreign objects
under underneath the
cover, and which is strong enough to protect the underlying surface from
unwanted physical
contact. It would also be preferable if the protective cover were water
resistant and reusable.
SUMMARY OF THE INVENTION
The present invention is directed to a device and method for protecting
bathing fixtures
during the construction of a building.
Accordingly, in one aspect of the invention, the invention comprises a liner
that is inserted into a
bathtub, having an interior surface and a deck, to protect the bathtub during
the construction of a
building, the liner comprising a unitary pre-molded flexible polymer foam
liner formed to match
the contours of the interior surface and the deck.
In one aspect of the present invention, the invention comprises a liner that
is inserted into a
shower unit to protect the shower unit during the construction of a building,
the shower unit
having an interior surface and an upper rim, the liner comprising a unitary
pre-molded flexible
polymer foam liner formed to match the contours of the interior surface and
the upper rim.
In one aspect of the present invention the invention comprises a unitary pre-
molded foam liner
for a bathing fixture that is pre-molded by spraying liquid foam onto a
bathing fixture mold.
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CA 02551357 2006-06-30
In one embodiment, the liner has pre-formed holes to correspond with openings
in the
bathing fixture. In one embodiment the polymer is polyurethane. In another
embodiment the
polymer is rubber, and in a further embodiment, the polymer is silicone.
In a further aspect of the invention, the invention comprises a method of
protecting a bathtub
having a deck and an interior surface during the construction of a building
comprising the steps
of:
(a) pre-molding a unitary polymer foam liner by spraying a polymer foam in
liquid
form onto a mold of the bathtub and removing it once the polymer foam
solidifies;
(b) inserting the polymer foam liner in the bathtub so the deck and the
interior surface
are completely covered;
(c) cutting holes in the polymer foam liner to correspond with holes in the
interior
surface and deck; and
(d) removing the polymer foam liner and any debris contained therein upon
completion of the construction.
In a further aspect of the invention, the invention comprises a method of
protecting a shower unit
having an interior surface and an upper rim during the construction of a
building comprising the
steps of:
(a) pre-molding a unitary polymer foam liner by spraying a polymer foam in
liquid
form onto a mold of the shower unit and removing it once the foam solidifies;
(b) inserting the polymer foam liner in the shower unit so the upper rim and
the
interior surface are completely covered;
(c) cutting holes in the foam liner to correspond with holes in the interior
surface; and
(d) removing the polymer foam liner and any debris contained therein upon
completion of the construction.
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BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of an exemplary embodiment with
reference
to the accompanying simplified, diagrammatic, not-to-scale drawings. In the
drawings:
Figure 1 is a diagrammatic depiction of a conventional bathtub.
Figure 2 is a cross sectional view of a conventional bathtub.
Figure 3 is a diagrammatic depiction of a conventional shower unit.
Figure 4 is a cross sectional view of a conventional shower unit.
Figure 5 is a cross sectional view of a conventional bathtub with one
embodiment of the
present invention inserted into it.
Figure 6 is a cross sectional view of a conventional shower unit with one
embodiment of
the present invention inserted into it.
DETAILED DESCRIPTION OF THE INVENTION
Scope
The present invention provides for a method and device for protecting bathing
fixtures during the
construction of a building. When describing the present invention, all terms
not defined herein
have their common art-recognized meanings. To the extent that the following
description is of a
specific embodiment or a particular use of the invention, it is intended to be
illustrative only, and
not limiting of the claimed invention. The following description is intended
to cover all
alternatives, modifications and equivalents that are included in the spirit
and scope of the
invention, as defined in the appended claims.
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CA 02551357 2006-06-30
Definitions
In this patent the following words are intended to have the following meaning:
1. "Bathing fixtures" shall collectively refer to bathtubs and shower units.
2. "Foam" shall mean a substance that is formed by trapping many gas bubbles
in a liquid or
solid.
3. "Polymer" shall mean a naturally occurring or synthetic compound consisting
of large
molecules comprising of a linked series of repeated monomers. Suitable
polymers
described herein include polyurethane, rubber and silicone.
All terms not defined herein have their common art-recognized meanings.
Description
The present invention is directed to a device and method of protecting bathing
fixtures during the
construction of a building. Figures 1 and 2 show a conventional bathtub (12)
having a deck (14)
and an interior surface (20) comprising a floor (18) and a dam (16). The floor
(18) has a drain
hole opening (24) and Figures 1 and 2 show faucet holes in the deck (14) and
the dam (16)
respectively. There is also commonly an overflow opening (26) as seen in
Figure 2. Figures 3
and 4 depict a conventional shower unit (30) having an upper rim (32) and an
interior surface
(38), the interior surface comprising a floor (36) and at least one wall (34).
The floor (36) has an
opening for a drain hole (24) and a wall may have an opening, or openings (22)
for a faucet as
shown in Figures 3 and 4. It should be understood that the present invention
may be used with
shower units and bathtubs made from any material including with out limitation
metal, vinyl and
fiberglass. It should be further understood that the present invention may be
used with shower
units and bathtubs of any design and shape including those having additional
features such as
seats and integral soap ledges.
The protective device is a unitary pre-molded polymer foam liner (40) that is
flexible yet strong
enough resist tearing and puncture through the regular wear that bathing
fixtures are subjected to
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CA 02551357 2006-06-30
during the construction process. The polymer foam is preferably thick enough
and dense
enough to cushion the blow of impact of any undesired physical contact from
such things as
dropped tiles or tools. The polymer is also preferably water resistant. Any
suitable polymer may
be used. Preferred polymers include polyurethane, rubber and silicone. It has
been found by the
inventor that if polyurethane foam is used, a layer of foam from one quarter
to half an inch thick
will provide adequate cushioning however, the thickness of the foam may be
increased if greater
protection is desired. It has also been determined that polyurethane foam
having a six pounds
per cubic foot density rating is a suitable type for use however, the density
of the foam can be
increased if greater protection is desired.
The liner (40) is inexpensive and simple to produce. The polymer foam in
liquid form is sprayed
in a relatively uniform layer onto a mold of the bathing fixture that is to be
protected. The mold
may be specifically constructed, or alternatively, it may simply comprise a
bathtub or shower
unit of the corresponding model to be protected that has been modified to be
suitable for use as a
mold. The mold may be coated with releasing agent prior to the application of
the polymer
foam. All surfaces of the bathtub requiring protection are covered with the
liquid polymer foam
on the corresponding mold. The polymer foam is applied to the desired depth.
The polymer
foam is allowed to dry and solidify and is then peeled as a single piece from
the mold. The
resulting light-weight pre-molded polymer foam liner may be rolled or folded
to facilitate
transportation and shipping to the user, and ultimately to the worksite.
As shown in Figures 5 and 6, the liner is inserted into the bathtub (12) or
shower unit (30) so that
all surfaces that require protection are covered. In the bathtub (12) the
liner (40) covers the
interior surface (20) and the deck (14). In the shower unit (30) the liner
(40) covers the interior
surface (38) and the upper rim (32). As shown in the figures, the liner may be
extended beyond
the deck (14) and the upper rim (32) to prevent slippage of the liner (40)
within the bathing
fixture. As can be seen in Figures 5 and 6, by virtue of its shape, the pre-
molded liner (40) is in
close physical contact with the entire interior surface of the bathing fixture
thereby preventing
the entry of any debris or waste between the liner and the interior surface of
the bathing fixture.
The pre-molded liner (40) will remain in place even when subjected to external
forces such as
feet and does not require any additional attachment means. The liner (40) is
water resistant and
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CA 02551357 2006-06-30
can be reused multiple times. At the completion of the construction process,
the
liner (40) may be removed form the bathing fixture in the same manner that a
garbage bag is
removed from a garbage can, thereby removing all accumulated debris and waste
at once.
The present invention is very easy to modify to create holes that match the
holes in the bathing
fixture for such things as drain holes, faucets and jets. Holes may be pre-
formed in the liner (40)
during the: molding process. However, although standard designs are used for
bathing fixtures,
the placement and configuration of the holes in the fixture varies greatly.
The liner (40) of the
present invention may be inserted in the bathing fixture without any holes and
then when its is
time to plumb the fixture in, holes may be cut in the liner very easily using
a craft knife or other
suitable cutting implement. Alternatively, if the model of bathing fixture has
openings that are
consistently placed such as the drain hole or the overflow opening, then
corresponding openings
may be formed in the liner (40) at the manufacturing stage. This beneficial
aspect of the liner
(40) means that trades people will not be impeded in their activities
involving the openings in the
bathing fixture and thus, the liner will be more likely not to be removed and
discarded. This is a
significant improvement on rigid liners that are difficult and cumbersome to
try modify in such a
manner. The present liner (40) may be modified quickly and efficiently to
accommodate the
myriad of opening configurations.
The use of'the liner (40) will now be described in relation to the protection
of a bathtub, however
it will be understood that the method described would have equal application
to a shower unit.
The first step is to obtain a mold of the bathtub that requires protection.
Releasing agent is
applied to the mold and then liquid polymer foam is applied in a uniform layer
to the deck (14)
and interior surface (20) to the desired depth. Any suitable method of
application of the polymer
foam may be used including spraying. If desired, holes may be preformed in the
liner at this
stage to correspond with standard openings in the bathing fixture such as
drain holes and
overflow openings. The polymer foam is allowed to dry and the liner is then
peeled from the
mold. Curing agents as would be used by one skilled in the art may be used to
promote the
solidification of the liquid polymer foam. The pre-molded liner (40) is then
transported to the
worksite and is placed in the bathtub (12) and aligned so that it covers the
entire interior surface
(20) and the deck (14). A knife can then be used to cut holes in the liner
(40) to create holes that
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are aligned with, and correspond to, the holes in the bathtub (12) such as the
faucet holes (22).
Upon completion of the construction, the top section of the liner (40) located
on the deck (14) is
gathered and the liner (40) is lifted out of the bathtub with all of the
debris and garbage contained
within the liner (40). The polymer foam is strong enough to support the weight
of the debris
without ripping. The garbage and debris is discarded and the liner may be
cleaned and used for
another job.
As will be apparent to those skilled in the art, various modifications,
adaptations and
variations of the foregoing specific disclosure can be made without departing
from the scope of
the invention claimed herein.
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