Note: Descriptions are shown in the official language in which they were submitted.
CA 02828555.2013-09-26
MOLDED STACKABLE BATHTUB WITH APRON AND MOUNTING ASSEMBLY
BACKGROUND OF THE INVENTION
[0001] This application claims the benefit of United States Provisional
Patent
Application Serial Number 61/708,079 filed October 1, 2012, the complete
disclosure of which is hereby expressly incorporated by reference.
[0002] This invention relates to a bathtub having an integrated front
apron,
and in particular, to a bathtub having a front apron and can be stacked in a
nested
arrangement for shipment, and further includes a strip and locking clip
assembly for
use in mounting the bathtub when installed.
[0003] Bathtubs that are molded with an integral apron front typically
include
apron supports or struts extending between the apron and tub to stabilize the
apron. However, such apron supports prevent this design of tub from being
nested
or stacked for shipment. Accordingly, such bathtubs are typically packaged
individually in a single carton. Although this makes it easy for a homeowner
to
easily purchase, pick up, deliver, and install such a bathtub, it is not
convenient for
a contractor working on a job site with a large number of bathtubs to install,
such as
in a high rise hotel. The contractor must take each individual bathtub to its
location,
or find some place to stack the bathtubs, and then unwrap each bathtub and
dispose of the packaging. This can be very inconvenient and time inefficient.
[0004] Accordingly, it is an object of the subject invention to provide a
bathtub having a front apron that can be nested and stacked for easier
shipment
and delivery to the job site. A further object of the invention is to reduce
packaging
weight and waste by shipping and delivering bathtubs in a nested stacked
arrangement rather than individually wrapped. A further object of the
invention is
that skids of the nested and stacked bathtub can be double stacked, which in
one
embodiment would provide 20 bathtubs in the same footprint of five standard
bathtubs on a truck.
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[0005]
It is a further object of the invention to provide a system and
components for mounting and stabilizing an apron not having supports or
struts,
when installing such a tub at the desired installation location.
SUMMARY OF THE INVENTION
[0006]
In one embodiment of the invention, a molded bathtub and mounting
assembly is provided that includes a molded bathtub having a basin, a rim
attached
to and extending at least partially around an upper end of the basin, and an
apron
attached to the rim and extending downwardly therefrom; and a mounting
assembly
including a mounting member and a mounting clip, and a gap located between a
portion of the mounting clip and the mounting member, the gap configured to
receive a lower end of the apron.
[0007]
Multiple bathtubs may be stacked together in an inverted position
with an upper bathtub receiving the basin of a lower bathtub in an open space
or
cavity of the upper bathtub defined by the basin therein. The bathtub is free
of
support struts extending between the apron and the basin, and further may
include
gussets mounted to and extending between the apron and the rim. The gussets
may have a long leg and a short leg, the long leg extending substantially
along the
height of the apron, the gusset further including a center span extending
between
the legs and a notch adjacent the center span coinciding with a corner where
the
apron and rim meet.
[0008]
The mounting member may have a generally elongated rectangular
configuration with the clip having a generally L-shaped configuration. The
clip may
include two legs and a projection that forms a gap with the mounting member.
[0009]
The projection may have a generally wedge-shaped configuration
including a front slope. The mounting assembly may be assembled with at least
two mounting clips, with a side edge of the mounting member located adjacent
shorter legs on the clips, and a bottom side of the mounting member located
adjacent longer legs of the clips. The other side edge of the mounting member
= may form the gap with the back side of the wedge shapes. The wedge shape
projection on the clips can have a pointed front edge.
[0010]
In another embodiment of the invention, a method of making molded
bathtubs capable of being stored and transported in a nested stacking
arrangement
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and method for stacking is provided comprising the steps of: providing a
molded
bathtub having a basin, a rim attached to and extending around at least a
portion of
an upper end of the basin, and an apron attached to and extending downwardly
from the rim; providing a pair of gussets having a long leg attached to and
extending down a significant portion of the height of the apron and short legs
attached to the rims, and further including a center span section and a notch
located adjacent a corner between the apron and the rim; and providing a
generally
open area between the apron and the basin free from supports extending
therebetween.
[0011] The steps may also include inverting a first bathtub and placing
the
rim of the bathtub on a pallet; inverting a second bathtub and inserting the
basin of
the first bathtub in an open space or cavity defined by the basin of the first
bathtub;
inverting a third and additional bathtubs and stacking the bathtubs in an
arrangement wherein the basin of each lower bathtub extends into the open
space
formed by the basin of the bathtub above. The steps may further include
placing
spacers between the rim of a lower bathtub and the rim on a bathtub above; and
providing a combined pallet and shipping frame for stacking two sets of nested
bathtubs. The shipping frame may include a second upper pallet on which a
second set of nested bathtubs is located.
[0012] Another embodiment of the invention is a method of installing a
molded bathtub having an integral apron and free from supports between the
apron
and basin, which comprise the steps of: providing a molded bathtub having a
basin, an integral rim, and an integral apron attached along one side of the
rim and
extending downwardly therefrom; providing a mounting assembly having at least
one gap for receiving and supporting the apron in an upright position; and
installing
the mounting assembly in an area where the bathtub is to be located.
[0013] The mounting assembly may include a generally elongated mounting
member and at least two clips arranged with the mounting member, wherein the
clips have a generally L-shaped configuration with a pair of legs and a
projection
extending from one of the legs that forms the gap with the mounting member.
The
molded bathtub is free from supports extending between the apron and the
basin.
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,
,
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above-mentioned and other features and objects of this
invention
and the manner of obtaining them will become more apparent and the invention
itself will be better understood by reference to the following description of
embodiments of the present invention taken in conjunction with the
accompanying
drawings, wherein:
[0015] Figure 1 is a perspective view of a standard bathtub
inverted to show
apron supports that prevent nested stacking;
[0016] Figure 2 is a perspective view of an inverted bathtub in
accordance
with the subject invention including a nested stacking design;
[0017] Figure 3 is a perspective view of a mounting strip
including a corner
lock bracket;
[0018] Figure 3A is an enlarged view of the area indicated in
Figure 3
showing greater detail of the corner locking bracket attached to the mounting
strip;
[0019] Figure 4 is a perspective view of the mounting strip with
the corner
locking brackets removed;
[0020] Figure 5 is a side view of the mounting strip of Figure 4;
[0021] Figure 6 is a planned view of the mounting strip of Figure
4;
[0022] Figure 7 is a perspective view of the corner locking
bracket shown in
Figures 3 and 3A and removed from the mounting strip;
[0023] Figure 8 is a side view of the corner locking bracket of
Figure 7;
[0024] Figure 9 is a top planned view of the corner locking
bracket of Figure
7;
[0025] Figure 10 is an end view of the corner locking bracket of
Figure 7;
[0026] Figure 11 is an upright view of the bathtub;
[0027] Figure 12 is an end view of the bathtub of Figure 11
showing the
configuration of the apron support gusset;
[0028] Figure 13 is a perspective view of a series of nested and
stacked
bathtubs in accordance with the present invention;
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,
[0029] Figure 14 is an end view of the stacked bathtubs in Figure
13;
[0030] Figure 15 is a perspective view of two sets of stacked
bathtubs
stacked one upon the other;
[0031] Figure 16 is a side view of the two sets of nested and
stacked
bathtubs of Figure 15;
[0032] Figure 17 is an end view of the two sets of nested and
stacked
bathtubs of Figure 16;
[0033] Figure 18 is a perspective view of the mounting strip and
corner
locking brackets installed on site for installation of the bathtub;
[0034] Figure 19 is a perspective view of the bathtub and is
mounted to the
mounting strip and corner locking bracket;
[0035] Figure 20 is a perspective view showing verification of
squareness of
the installation of Figure 19; and
[0036] Figure 21 is a perspective view of four sets of stacked
bathtubs
stacked one upon the other.
[0037] Corresponding reference characters indicate corresponding
parts
throughout the several views. Although the drawings represent embodiments of
the present invention, the drawings are not necessarily to scale and certain
features may be exaggerated in order to better illustrate and explain the
present
invention. The exemplification set out herein illustrates 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 EMBODIMENTS OF THE INVENTION
[0038] For the purposes of promoting an understanding of the
principles of
the invention, reference will now be made to the embodiments illustrated in
the
drawings, which are described below. It will nevertheless be understood that
no
limitation of the scope of the invention is thereby intended. The invention
includes
any alterations and further modifications in the illustrated devices and
described
methods and further applications of the principles of the invention, which
would
normally occur to one skilled in the art to which the invention relates.
CA 02828555 2013-09-26
,
,
[0039]
Now referring to Figure 1, a standard molded bathtub is shown,
generally indicated as 10, and in an inverted position. Bathtub 10 includes an
integrally molded front apron 12 and supports or struts 14 attached to and
extending between apron 12 and a bottom 16 of a basin 17 of bathtub 10. Also
attached to and extending down from bottom 16 are feet 18 on which bathtub 10
stands upon when installed. Bathtub 10 also includes an upper rim or ledge 20
extending around the top thereof and to which apron 12 is attached.
[0040]
As discussed above, bathtub 10 is ideal for individual packaging and
sale, and struts 14 provide ample support for apron 12 when the unit is
installed.
However, as should be appreciated by one skilled in the art, struts 14
preclude
bathtub 10 from being nested and stacked together as the rim 20 of a bathtub
to be
shipped over top of bathtub 10 would encounter the struts 14 on the lower
bathtub
and prevent stacked nesting of the tubs.
[0041]
Now referring to Figure 2, one embodiment of a molded bathtub in
accordance with the subject invention is shown, generally indicated as 110.
Bathtub 110 includes an integrally molded and attached front apron 112.
However,
instead of struts or supports 14 as found on bathtub 10, bathtub 110 only has
end
gussets 114. Also, similar to bathtub 10, bathtub 110 includes a basin 117
having
a bottom 116 from which support feet 118 extend, and an upper rim or ledge 120
to
which apron 112 is attached. As is shown in Figure 2, gussets 114 extend
between
and are attached to apron 112 and rim 120.
[0042]
Now referring to Figures 3 and 3A, a mounting assembly used in
installing bathtub 110 is shown, generally indicated as 130. Mounting assembly
130 includes a furring or mounting strip 132 and a clip or bracket 134. As
shown in
Figures 4-6, furring strip 132 has a generally rectangular configuration
including a
top side 140, a bottom side 141, side edges 142 and 143, and ends 144 and 145.
In the embodiment shown, furring strip 132 does not include any holes or
irregularities; however, it should be realized that mounting holes may be used
to
mount clip 134 or recesses added to make flush mounting of clip 134. Furring
strip
132 may be made from plywood or a laminated wood material, or alternately, a
metal, such as aluminum or stainless, or a suitable plastic, may be used for
the
furring strip.
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,
,
[0043] Details of clip 134 are shown in Figures 7-10. In the
embodiment
shown, clip 134 has a generally L-shaped configuration including a shorter
upstanding leg 150 and longer lower leg 152 having a generally wedge-shaped
configuration 154 on the end thereof. Wedge shape 154 includes a back side
156,
a front slope 158, a radius 159 between back side 156 and front slope 158, and
a
pointed front end 160. Clip 134 may be manufactured from an ABS plastic and
adhered to furring strip 132, or alternately, may be attached with fasteners
or other
well known attachment means. In addition, clip 134 may be manufactured from
other materials, such as aluminum or stainless steel.
[0044] Clips 134 are attached or otherwise assembled with furring
strips 132
as shown in Figure 3A. The bottom side 141 of the furring strip is placed on
top of
bottom leg 152 of clip 134, and side edge 143 (or alternately side edge 142)
is
placed against leg 150 of clip 134 as shown. This creates a gap 161 between
back
side 156 of the wedge shape 154 of clip 134 and the front side edge 142 of
furring
strip 132. Gap 161 is for receipt of the bottom end of apron 112 when
installed at a
site as discussed in further detail below.
[0045] Now referring to Figures 11 and 12, bathtub 110 is shown in
an
upright position wherein it can be seen that basin 117 defines an open space
or
cavity 122 for holding water for bathing. In addition, further detail of
gussets 114 is
shown in Figures 11-14. Gussets 114 include a long leg 162 attached to apron
112
and a short leg 164 attached to rim 120. Gusset 114 also includes a center
span
166 having a notch 167 where apron 112 and rim 120 meet. Gusset 114 may be
manufactured from an ABS plastic or corrosion-resistant metal, such as
aluminum
or stainless steel.
[0046] Now referring to Figures 13 and 14, an arrangement showing
seven
bathtubs 110 nested and stacked on a pallet 170 is shown. As can be seen, the
bathtubs 110 stack quite nicely and shipping spacers 172 are provided in each
corner attached to or placed on the bottom side of rim 120 so that the rim 120
on
the adjacent bathtub can rest thereon and also prevent rim 120 from
encountering
gussets 114. Shipping spacers 172 may be manufactured from a corrugated
cardboard or plastic material or alternately, hard foam, wood, or other
suitable
material may be used.
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[0047] Now referring to Figures 15-17, bathtubs 110 are shown nested and
stacked in a double stacking arrangement of two sets of nested and stacked
bathtubs. With this arrangement, 20 bathtubs can be stacked on a truck in the
same footprint of five standard bathtubs. As an example, the present
arrangement
may allow a total of 600 nested and stacked bathtubs on a truck compared to
150
standard bathtubs. The bottom set of 10 nested and stacked bathtubs 110 are
contained within a combined pallet and shipping frame 180. Pallet and shipping
frame 180 includes a lower pallet portion 182 similar to pallet 170 and an
upper
pallet portion 184, which is also similar to pallet 170. As is shown, the
lower set of
nested stacking bathtubs 110 rests on lower pallet portion 182, and the upper
set of
nested stacking bathtubs 110 sits on upper pallet portion 184. Extending
between
lower pallet portion 182 and upper pallet portion 184 are a number of vertical
frame
members 186. More or less vertical frame members may be used as desired.
Pallet and shipping frame 180 also includes angled frame members 188 to
increase
the stability thereof. The number, position, and orientation of angled frame
members 188 may be varied as desired.
[0048] Now referring to Figure 21, bathtubs 110 are shown nested and
stacked in a stacking arrangement of four sets of nested and stacked bathtubs
110.
In the example shown, each set includes seven nested bathtubs stacked together
for a total of twenty-eight bathtubs being stacked one upon the other. The
bathtubs
110 in Figure 21 are shown stacked in the same combined pallet and shipping
frames 180 as shown in Figures 15-17. Such an arrangement allows for very
efficient stacking of bathtubs in a warehouse, ship, etc.
[0049] Now referring to Figures 18-20, installation of bathtubs 110 and
use of
mounting assemblies 130 is shown. As shown in Figure 18, the mounting
assembly is mounted to the floor with side edge 143 of furring strip 132
facing
towards the back wall and clip 134 facing outwardly. Mounting assembly 130 may
be nailed, screwed or attached with an adhesive. Mounting strip 130 is used to
provide additional support to the apron since struts 14 have been removed to
facilitate the nested stacking. Before mounting assembly 130, it is preferable
to
mark the subfloor based upon the dimensions of the bathtub to be installed.
The
front line of furring strip 132 may be marked on the subfloor, and the furring
strip
secured firmly behind the line. The bathtub is installed in accordance with
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instructions with the bottom of apron 112 positioned in gaps 161 of mounting
assembly 130. (See Figure 19.) Apron corners should be guided into the gap and
once installed therein, the installation should be checked with a square 195
to verify
that the apron is set all the way in at 900. (See Figure 20.) If the apron is
not at
900, then the bathtub should be removed, and the location of the furring strip
should
be moved forward or backward accordingly. Thusly installed, the mounting
assembly holds the apron straight and securely during use thereof.
[0050]
While the invention has been taught with specific reference to these
embodiments, one skilled in the art will recognize that changes can be made in
form and detail without departing from the spirit and scope of the invention.
The
described embodiments are to be considered, therefore, in all respects only as
illustrative and not restrictive. As such, the scope of the invention is
indicated by
the following claims rather than by the description.
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