Abstract:
A fastener for use in air massage systems used with a bathtub that includes a shell having at least two layers with at least one hole being defined through the shell. The fastener, for instance in the form of a rivet, comprises a hollow body adapted to extend through the hole in the shell and a securing mechanism provided for anchoring the fastener in the hole and for retaining together the layers of the shell. The securing mechanism can comprise enlarged distal and proximal elements provided at opposed ends of the hollow body and adapted to be disposed against inner visible and outer hidden surfaces of the shell. The proximal element includes a decorative head adapted to at least partly overlie the visible surface of the shell.

Description:
[0001]     This application claims priority on Canadian Patent Application No. 2,410,110, filed on Oct. 29, 2002 by the present applicant, and on U.S. provisional Patent Application No. 60/422,120, filed on Oct. 30, 2002 by the present applicant.  
       BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to bathtub air massage systems and, more particularly, to such systems having hidden air jets and/or channel-type air delivery means.  
         [0004]     2. Description of the Prior Art  
         [0005]     The Channel system, e.g. as in the Ultra™ bathtub, consists in surrounding a bathtub with a fibreglass air cavity. Thirty to ninety holes of more or less ⅛″ in diameter are defined through the bathtub. Air is propelled in the cavity by a blower and then escapes through each hole to create turbulence in the water.  
         [0006]     Also known from Canadian Application No. 2,356,494 (in the name of C.G. Air Systemes Inc.) is an air massage system wherein upstream of the holes defined in the shell of the bathtub (i.e. behind this shell), hidden air jets are provided to deliver pressurised air through the holes and into the bathtub&#39;s cavity. These air jets are connected to a blower via tubing that is also hidden.  
         [0007]     Such holes defined in the shell of the bathtub may define slightly sharp edges and are not necessarily very aesthetic.  
       SUMMARY OF THE INVENTION  
       [0008]     It is therefore an aim of the present invention to provide a decorative member for lining holes defined in the shell of a bathtub provided with an air massage system.  
         [0009]     It is also an aim of the present invention to provide such a decorative member that also acts as a fastener to hold together the various layers forming the shell.  
         [0010]     It is a further aim of the present invention to provide a tool for installing the decorative member to the shell.  
         [0011]     It is a still further aim of the present invention to provide a method for installing the decorative member to the shell.  
         [0012]     Therefore, in accordance with the present invention, there is provided a fastener for use in air massage systems used with a bathtub having a shell having at least two layers, at least one hole being defined through the shell, comprising a hollow body adapted to extend through said hole and securing means provided for anchoring said fastener in the hole and for retaining together the layers of the shell.  
         [0013]     Also in accordance with the present invention, there is provided a decorative device for use in air massage systems used with a bathtub having a shell and at least one hole defined through the shell, comprising a hollow body adapted to extend through said hole and a decorative member provided at a visible end of the decorative device and defining an opening in fluid communication with said hollow body such that pressurised air provided by the air massage system is conveyed through said decorative device and into the bathtub.  
         [0014]     Further in accordance with the present invention, there is provided a fastener in combination with a bathtub provided with an air massage system, said bathtub comprising a shell defining a bathing cavity and having at least two juxtaposed layers defining opposed visible and hidden surfaces of said shell, a plurality of holes being defined through said shell such that pressurised air delivered by said air massage system is conveyed through said holes from said hidden surface to said visible surface and into said cavity, said fastener being provided for each of said holes and comprising a hollow body extending through said hole and securing means provided for anchoring said fastener in said hole and for retaining together said layers of said shell.  
         [0015]     Still further in accordance with the present invention, there is provided a method of installing a fastener into a hole of a shell of a bathtub provided with an air massage system, comprising the steps of: (a) providing a hollow fastener; (b) positioning said fastener on a tool; (c) inserting said tool and said fastener carried thereby in said hole via a first direction; (d) displacing said tool in a second direction different than said first direction such that said tool deforms said fastener and secures said fastener to said hole; and (e) removing said tool from said hole. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof, and in which:  
         [0017]      FIG. 1  is a vertical cross-sectional view of a bottom corner section of a bathtub provided with an air massage system and showing a hollow decorative fastener in accordance with the present invention;  
         [0018]      FIG. 2  is a perspective view of the bathtub provided with the air massage system;  
         [0019]      FIGS. 3   a  to  3   d  are cross-sectional views showing successive steps in the installation of the hollow decorative fastener into a hole defined in the shell of the bathtub, in accordance with a first embodiment of the present invention; and  
         [0020]      FIGS. 4   a  to  4   d  are cross-sectional views showing successive steps in the installation of the hollow decorative fastener into a hole defined in the shell of the bathtub, in accordance with a second embodiment of the present invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0021]     Referring to  FIG. 2 , a bathtub B is shown provided with an air massage system S. The bathtub B includes a shell  10  that defines an inner cavity within which water can be received in a well known manner.  
         [0022]     The air massage system S includes a blower  12  (which may enclose a heating element), a flexible or rigid main piping  14  connecting the blower  12  to a manifold  16 , and a series of rigid or flexible branch pipes  18  that connect the manifold  16  to downstream air jets  20  that are concealingly mounted behind the shell  10 . A number of holes  22  ( FIG. 1 ) are defined through the shell  10  of the bathtub B with an air jet  20  being sealingly mounted to a hidden surface of the shell  10  of the bathtub B opposite each hole  22 . The air massage system S may also include a sequencer and an electronic controller (not shown).  
         [0023]     As seen in  FIG. 1 , a channel  24  can be provided on the sides of the bathtub B with air from the blower  12  being directed into the channel  24  and through further holes  26  defined in the shell  10  opposite the channel  24 .  
         [0024]     Each hidden air jet  20  is illustrated mounted against the hidden outer surface of the shell  10  of the bathtub B and to a fitting  28 , such as an elbow (herein shown), a nipple or a Tee. The air jet  20  includes a jet body  30  that comprises an exteriorly threaded hollow tube  32  and an end flange  34 . A unidirectional flow mechanism is provided within the hollow tube and can take the form of any water non-return device.  
         [0025]     The elbow fitting  28  comprises an interiorly tapped hollow tube  36 . A flange  38  is provided at a distal outlet of the tapped hollow tube  36 . The flange  38  defines an annular groove  40  upon which rests an annular seal  42 . A proximal inlet  44  of the fitting  28  extends laterally from the tapped hollow tube  36 , and comprises a number of successive and parallel exterior annular wedges  46  for a sealed connection to a branch pipe  18 .  
         [0026]     Air is blown through the flexible branch pipe  18  and enters the hidden air jet  20  by the inlet  44 . It fills the tapped hollow tube  36  and builds sufficient pressure to open and flow through the unidirectional flow mechanism. Then, it exits in the bathtub B through the holes  22  and creates a turbulence in the water filling the bathtub B.  
         [0027]     Air blown into the channel  24  is conveyed through holes  26  defined along the channel  24  which extends peripherally around a bottom corner of the bathtub B. A variation of the Channel-type bathtub replaces the channel  24  by a cavity substantially extending along the hidden outer surface of the shell of the bathtub, thereby defining a plenum which in fact extends across the complete bottom of the bathtub and also possibly behind the side wall thereof. Similarly, the plenum conveys air through holes such as holes  26 .  
         [0028]     It is possible for air jets  20  to be mounted in the channel  24  or the plenum of the bathtub, in a bonded manner to the hidden outer surface of the shell  10  of the bathtub B, whereby it is possible to remove the flexible pipes  18  and the elbow fittings  28 , with the hidden air jets  20  being simply fed with pressurised air contained in the channel  24  or plenum while still preventing the infiltration of bathtub water in the channel  24 .  
         [0029]     In all of the above embodiments, the air massaging system S is completely hidden by way of the use of the air jets  20  (and channel  24 ), which only leaves the holes  22  (and  26 ) of this air massaging system S to be visible.  
         [0030]     The unidirectional flow mechanism provided in the air jet  20  allows for the free release of air in the bathtub B. Once the air pressure in the flexible pipes  18  is reduced, upon the end of operation of the system S for example, the unidirectional flow mechanism closes, thereby preventing the bathtub water from entering in the flexible pipes  18  and so causing, e.g. by its stagnation, a contamination of the flexible pipes  18  and of the remaining piping network of the air massage system S. As air is the sole fluid in contact with the flexible pipes and with the piping network of the air massage system, the hidden air jet ensures a high hygiene level.  
         [0031]     The unidirectional flow mechanism may have different configurations. It can be a check valve with a spring-loaded piston and/or one (or more) spring-loaded plastic, stainless steel, glass or rubber ball, with a rubber flap or flaps from another material, a magnetic valve, a flexible diaphragm, a combination of the above enumeration and/or any other unidirectional flow mechanism to ensure the water-tightness of the air jet J.  
         [0032]     Also, the elbow fitting  28  can be replaced by a Tee fitting, or other. This configuration increases the flow of incoming air through the inlet of the hidden air jet  20 , and consequently, the turbulence in the bathtub B.  
         [0033]     It is noted that the shell  10  of the bathtub B, as seen in  FIG. 1 , comprises two composite layers, i.e. an inner visible layer  48  (for instance made of acrylic) and an underlying outer hidden layer  50  (for instance made of fibre glass).  
         [0034]     In accordance with the present invention, there is provided a hollow decorative fastener F (see  FIG. 1 ), generally in the form of a rivet. The fastener F is engaged in each of the holes  22  and  26  and accomplishes the following functions. First, it retains both the shell layers  48  and  50  together. Second, it conceals any sharp edge defined at the outlet of any of the holes  22  and  26 , that is where the holes  22  and  26  open up into the inside cavity formed by the shell. This prevents a user located in the bathtub B from being possibly scratched, or other, by the visible edges of the holes  22  and  26 . Finally, the fastener F provides an aesthetic finish around the holes  22  and  26  within the bathing cavity of the bathtub B.  
         [0035]     More particularly, the fastener F, when installed as in  FIG. 1 , includes a tubular member  52 , a decorative hollow head  54  at the downstream visible end thereof, and an enlarged upstream hidden end  56 , wherein the head  54  and the enlarged end  56  (best seen in  FIG. 3   d ) retain the shell layers  48  and  50  in a contacting laminate relation thereby eliminating the possibility that a space is formed between the shell layers  48  and  50  adjacent the holes  22  and  26 . To achieve this final position, the fastener F is deformed in a rivet-like way, as explained in more detail hereinafter.  
         [0036]     The fastener F can be made of corrosion-proof metals, that can be polished, sanded, painted, plated or chemically treated to increase its finish, its mechanical properties, its resistance to corrosion, etc.  
         [0037]     The fastener F can also be made of composite or plastic materials that can be deformed to compress the composite shell layers  48  and  50  in the same manner as the metallic fastener. Such a non-metallic fastener can be installed by heating, adhesion, welding, ultrasound, pressure fit, etc. The non-metallic fastener can also be polished, sanded, painted, plated or chemically treated to increase its finish, its mechanical properties, its resistance to corrosion, etc.  
         [0038]     The fastener F is used on bathtubs such as the bathtub B illustrated in  FIG. 2 , which is provided with a bottom or side air injection system. The fastener F is used to solidify and/or beautify the holes  22  and  26  defined through the various juxtaposed composite layers  48  and  50  that form the shell  10  of the bathtub B. The fastener F provides a superior finish that prevents sharp edges defined on the upper layer  48  and around the holes  22  and  26  from injuring the user, and also improves the look in the bathtub B at these holes  22  and  26  by offering various finishes and colors.  
         [0039]     As seen sequentially in  FIGS. 3   a  to  3   d , the fastener F is installed in the holes  22  and  26  as follows. The fastener F in its initial shape seen in  FIG. 3   a  is mounted around a cylindrical carrier  58  of a tool T that includes an enlarged flared end  60  distally of the carrier  58  and that is larger than the distal end  56  of the fastener F to prevent the fastener F from falling off the tool T. The tool T and the fastener F carried thereby are then inserted through the hole  22 / 26 , along arrows  62  in  FIG. 3   a , until they reach the position shown in  FIG. 3   b . The tool T is then withdrawn from the hole  22 / 26 , i.e. along arrows  64  in  FIG. 3   c , whereby the enlarged end  60  of the tool T causes via its flare  66  the enlarged end  56  of the fastener F to deform (i.e. flatten while further enlarging) while then also causing the tubular member  52  of the fastener F to radially expand generally into contact with the shell walls defining the hole  22 / 26 . As seen in  FIG. 3   d , the tool T is completely removed from the hole  22 / 26  and from the fastener F, with the latter being in its final installed position where it compresses the layers  48  and  50  of the shell  10  to thus avoid a possible delamination thereof and to avoid water infiltration in the shell  10  that could cause water leaks.  
         [0040]     As an alternative to the sequence illustrated in  FIGS. 3   a  to  3   d , another sequence in accordance with a second embodiment of the present invention is illustrated in  FIGS. 4   a  to  4   d . More specifically, a variation to the fastener F is illustrated at F′. The fastener F′ is similar to the fastener F in that it has a decorative hollow head  54  and an enlarged upstream hidden end  56 . The fastener F′ has a tubular member  52 ′ defining a pair of legs by a longitudinal slot.  
         [0041]     A tool T′ is to be used for the installation of the fastener F′ to the shell  10  of the bathtub. The tool T′ has a carrier  58 ′ that can translate longitudinally with respect to a remainder of the tool T′. The tool T′ also has a cavity  60 ′, shaped so as to receive the head  54  of the fastener F′.  
         [0042]     The fastener F′ in its initial shape seen in  FIG. 4   a  is mounted around the cylindrical carrier  58 ′ of the tool T′. As seen in  FIG. 4   b , the hollow head  54  of the fastener F′ is received in the cavity  60 ′ of the tool T′, whereas the carrier  58 ′ is partially inserted into the tubular member  52 ′, as illustrated in  FIG. 4   b.    
         [0043]     Prior to the insertion of the faster F′ into the holes  22 ,  26  of the shell  10 , an adhesive  70  is optionally provided on an outer surface of the tubular member  52 ′. Thereafter, the fastener F′ may be inserted into the holes  22 ,  26  of the shell  10  in a first direction shown by arrows  62  of  FIGS. 4   a  and  4   c . The tool T′ exerts a pressure on the fastener F′ so as to insert the fastener F′ into holes  22 ,  26  of the shell  10  through the mating engagement of the hollow head  54  in the cavity  60 ′. The legs of the tubular member  52 ′ are inwardly deflected so as to enable the enlarged head  56  to pass through the holes  22 ,  26 . Once the enlarged head emerges out of the holes  22 ,  26 , the legs of the tubular member  52 ′ resiliently return to their initial position illustrated in  FIGS. 4   a  and  4   b . Therefore, at this position, the enlarged head overlaps the periphery of the holes  22 ,  26 , and prevents the fastener F′ from being removed from the shell  10 .  
         [0044]     Still referring to  FIG. 4   c , the carrier  58 ′ is further reciprocated as shown by arrow  62  (and arrow  64  in  FIG. 4   d ), with respect to a remainder of the tool T′, whereby it will exert a radial pressure on the legs of the tubular member  52 ′. This movement is optional, but ensures that the adhesive  70  is well spread and maintains the tubular member  52 ′ against the surface of the holes  22 ,  26 .  
         [0045]     Referring to  FIG. 4   d , the carrier  58 ′ is then translated in the direction illustrated by arrows  64 , whereby the tool T′ can be removed and the fastener F′ is installed in the shell  10  of the bathtub.  
         [0046]     The tools T and T′ can be manually operated, pneumatic, electric, or actuated using any other form of energy.