Abstract:
An injection molded shower stall assembly or bathtub assembly particularly for use in a recreational vehicle includes an injection molded tub or shower base, which includes an integrally formed drainpipe which is externally threaded and adapted to easily and permanently be connected to plumbing for the recreational vehicle. Injection molded walls are formed to surround either the shower stall or tub. The injection molded walls have lower edges that interfit with edges of the tub or shower stall in a way which prevents water from flowing behind the preformed walls and holds the lower edges of the preformed walls in position, eliminating the need for any type of penetrating fastener along the base of the walls. The walls are formed in multiple sections that fit one on top of the other, with interfitting lower and upper edges, again to reduce the need for penetrating fasteners and to hold the sections in position.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Showers and bathtubs in recreational vehicles typically include a molded base and some type of water impervious laminate applied to the walls, which direct water to the molded base. Typically the molded base has a drain opening and a drainpipe is fastened to the opening and connected to plumbing. 
         [0002]    The laminates used are typically relatively flimsy but they are used because they are lightweight, inexpensive and can withstand the vibrations of a moving vehicle. The drain, however, does present problems because there is generally no access to the drainpipe once the tub or stall is installed. One cannot see if there is any leakage occurring until it works its way through the floor. Also, the vibrations produced by the moving vehicle can easily cause the drainpipe to become loose, making leaks a significant concern. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention is premised on the realization that a more effective, aesthetically appealing shower or tub can be formed by molding the tub or the base with an integral threaded drainpipe. The base or tub further includes peripheral flanges which mate with injection molded sidewalls. The sidewalls are formed in sections that allow them to be easily installed within the vehicle in a stacked configuration to give the desired height of the sidewalls. These sidewalls, because they inter-fit, prevent water from leaking. Because they are injection molded, they are much stronger than typical laminates used in these applications. Further, fastening holes can be provided which can be easily covered by an adjacent section which again provides an aesthetically clean appearance. In one embodiment, they can be formed with three integral walls which prevents water from leaking at the corners. 
         [0004]    The objects and advantages of the present invention will be further appreciated in light of the following description of the drawings in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is a perspective exploded view of the present invention; 
           [0006]      FIG. 2  is a perspective view of the present invention; 
           [0007]      FIG. 3  is an enlarged perspective view of area  3  of  FIG. 1 ; 
           [0008]      FIG. 4  is an enlarged perspective exploded view of area  4  of  FIG. 1 ; 
           [0009]      FIG. 5  is a cross-sectional view taken at lines  5 - 5  of  FIG. 2 ; 
           [0010]      FIG. 6  is a cross-sectional view taken at lines  6 - 6  of  FIG. 2 ; 
           [0011]      FIG. 7  is a cross-sectional view taken at lines  7 - 7  of  FIG. 2 ; 
           [0012]      FIG. 8  is a bottom side perspective view of the shower base of the present invention; 
           [0013]      FIG. 9  is a perspective view, partially exploded, of an alternative embodiment of the present invention utilizing a bathtub; 
           [0014]      FIG. 10  is a perspective view showing assembly of the sidewalls of a alternative embodiment of  FIG. 9  of the present invention; 
           [0015]      FIG. 11  is a perspective view, partially exploded, of the embodiment shown in  FIG. 10 ; 
           [0016]      FIG. 12  is a perspective view of the alternative embodiment shown in  FIG. 10 ; 
           [0017]      FIG. 13  is an enlarged view of area  13  of  FIG. 10 ; 
           [0018]      FIG. 14  is an enlarged view of area  14  of  FIG. 11 ; 
           [0019]      FIG. 15  is an enlarged view of area  15  shown in  FIG. 11 ; 
           [0020]      FIG. 16  is cross-sectional view taken at lines  16 - 16  of  FIG. 12 ; 
           [0021]      FIG. 17  is a cross-sectional view taken at lines  17 - 17  of  FIG. 2 ; 
           [0022]      FIG. 18  is a cross-sectional view taken at lines  18 - 18  of  FIG. 2 ; 
           [0023]      FIG. 19  is a cross-sectional view taken at lines  19 - 19  of  FIG. 2 ; and 
           [0024]      FIG. 20  is a bottom perspective view of the bathtub shown in  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    The present invention can be in the form of a shower stall, as shown in  FIGS. 1-8  or a bathtub as shown in  FIGS. 9-20 . 
         [0026]    As shown in  FIG. 1 , a shower stall assembly  10  includes a base  12 , a first wall section  14 , a second wall section  16  and a third, upper wall section  18 . The base  12  includes a floor  20  and a bottom surface  22  and raised sidewalls  24 . The front  26  is open and would typically be enclosed by a glass enclosure or the like. 
         [0027]    Base  12  further includes a drain  30  which is molded as part of the base  12  and includes an integral, externally threaded drainpipe  32  extended below floor  20 . 
         [0028]    As shown in  FIGS. 1 and 2 , the base  12  rests on its bottom surface  22  mounted directly to the floor or can be raised above the floor of the recreational vehicle. In this latter case, a spacer  34  would be attached to the other edge of the base  12  as a trim piece. 
         [0029]    The base further includes a raised peripheral edge  38 , which runs continuously on first side  40  and second side  42  and (optional) rear corner side  44 . Peripheral edge  38  includes a first continuous rear flange  46  and a first continuous forward flange  50 , separated by a first channel  48 . As described hereinafter, this allows the first wall section  14  to be mounted on the base  12 , forming a connection that prevents water from flowing to the backside of the shower stall. 
         [0030]    The first wall section  14  includes a first wall  54 , a second wall  56  and a corner section  58 . The corner sections are optional as first wall  54  can be connected to second wall  56  as long as it conforms to peripheral edges  38 . The front surface  60  and wall section  14  is designed to direct water into the base  12  and the rear surface  62  is intended to be mounted against a wall of the recreational vehicle. First wall section  14  includes a bottom edge  64  and a top edge  66 . The bottom edge includes a second rear flange  68  and a second forward flange  70 , with a second channel  72  therebetween. 
         [0031]    The top edge includes an upwardly extending flange  74 , Also on either side of top edge  66  are first and second corners  76 ,  78 , respectively. Each corner  76 ,  78  includes first and second attachment tabs  80 ,  82 , which are designed to lie flush against the wall of the recreational vehicle, Top edge  66  further includes a first ledge  84  adjacent upper flange  74 . 
         [0032]    The second wall section  16  likewise has a bottom edge  88  and a top edge  90 . Bottom edge  88  includes a continuous third rear flange  92  and a forward edge  93 . As shown in  FIG. 7 , the upper flange  74  of the lower wall section fits between the third rear flange  92  of the bottom edge  88  and the forward edge  93 . The upper edge  90  of the second wall section  16  is identical to the upper edge  66  of the first wall section  14  and, likewise, the bottom edge  94  of third wall section  18  is identical to the bottom edge  88  of the second wall section  16  and therefore not described further in detail. As shown, the third wall section  18  includes one or more soap dishes  98  and the upper edge  96  is held in position by barbed plugs  97 , which extend through though top edge  96  into the walls of the recreational vehicle. However, any suitable fastener can be used. 
         [0033]    To install the shower stall of the present invention, the base is positioned as desired on the floor (not shown) of a recreational vehicle. In certain recreational vehicles, there is an area under the floor that allows for plumbing. In this case, the base  12  would be positioned on the floor (not shown) with drainpipe  32  extended through a hole (not shown) in the floor. If there is no area for plumbing under the floor, the base would be supported with wood framing (not shown) above the floor (not shown) and spacer  34  would be fixed to the base  12 , with the upper edge  102  resting in the lower edge  104  of the base, as shown in  FIG. 5 . An internally threaded fitting (not shown) would then be screwed onto the drainpipe  32  to form a permanent connection and the base  12  and the drain lines. 
         [0034]    The first wall section  14  is placed over the back edge of the shower base  12 , as shown in  FIGS. 3 and 6  and against two walls of the recreational vehicle (only wall  106  is shown in  FIGS. 4 and 7 ). The upper edge of the first wall section  14  is attached to the back wall  106  of the recreational vehicle using fastener  100  as shown in  FIGS. 4 and 7 . Wall section  16  is positioned on top of wall section  14 , with the lower edge of wall section  16  interfitting with the upper edge of first wall section  14  as shown in  FIGS. 4 and 7 . The upper edge  90  of wall section  16  is attached to the recreational vehicle&#39;s wall surfaces in the same manner as lower section  14  using attachment tabs  80 ,  82 . Finally the third wall section  18  is positioned on top of the second wall section  16  in the same manner and the top edge fastened to the recreational vehicle wall surface using barbed plugs that extend through the upper edge  96  of section  18  into the recreational vehicle walls holding section  18  in position. 
         [0035]    The individual sections are formed by injection molding. A wide variety of different polymers can be used, such as polyethylene, polypropylene, polyvinyl chloride and the like. Since the wall sections are formed as one piece, with additional sections stacked on top, the possibility of water leakage is minimized. Caulking is not required and due to the flexibility of the polymers, the installed shower stall can withstand the vibrations typically encountered with a recreational vehicle. Also, due to the interfitting construction, the shower stall can be installed very quickly and easily. 
         [0036]    As shown in  FIGS. 9-20 , features of the present invention can also be incorporated into a bathtub  110  used in a recreational vehicle. The tub  110  includes a floor or base  112 , sidewalls  114  and a peripheral ledge  116 . The base  112  incorporates an integral drainpipe  120 , which includes external threading  122 . The bottom surface of tub  110  includes ribbing  124  to provide further support. 
         [0037]    The tub  110  further includes a side edge lip  126 , shown more particularly in  FIGS. 13 and 16 , and a side panel or skirt  128 , which has an upper edge  130  that fits within a lower channel  132  of edge  126 . 
         [0038]    The tub  110  includes a first outer flange  134  that runs continuously along two sides and the back of the tub, and a continuous first inner flange  136  which runs parallel to continuous flange  134 . In this instance, outer refers to away from the center of the tub and inner refers to nearer the center of the tub. These are adapted to receive three sidewall panels  138 ,  140  and  142 . Second side panel, or rear side panel  140  includes first and second vertical side edges  144 ,  146 . As shown in  FIG. 19 , each of these side edges includes a vertical flange  148 , which includes a plurality of inwardly extended barbs  150 . Sidewalls  138  and  142  each have vertical inner edges  152  adapted to mate with the vertical flanges  148  of wall  140 . Each vertical edge  152  includes a channel  154  and a plurality of slots  156  adapted to receive the barbs  150 . Panels  138  and  142  also include outer vertical side edges  162 . Each side edge  162  includes a channel  164  adapted to receive a barbed flange  167  of a trim piece  168 , as shown in  FIG. 19 . 
         [0039]    The tub enclosure also includes three upper walls  170 ,  172  and  174 . These are identical to walls  138 ,  140  and  142 . As shown in  FIG. 15 , the bottom edge  200  of top panel  170  has a channel which receives an upper portion  184  of panel  138  with a back edge of panel  170  resting on ledge  186  of lower panel  138 . 
         [0040]    The tub enclosure of the present invention is installed by positioning the tub in a desired location surrounded by three adjoining walls of the recreational vehicle (not shown). A drainpipe is connected to the preformed threaded drain  120  and connected to the drainage system for the recreational vehicle. The three panel walls  138 ,  140  and  142  are then snapped together, as shown in  FIGS. 10 and 19 . The walls are then positioned in place over the tub ( FIG. 11 ), with the lower edges of the walls  188 ,  190 ,  192  that fit over continuous flanges  134 ,  136  of tub  110  in position as shown in  FIG. 14 . The panels are held to the wall by adhesive or barbed fasteners. This is then repeated with upper walls  170 ,  172  and  174 , with the lower edges  200 ,  202 ,  204  of the walls  170 ,  172  and  174  resting on the upper edges  194 ,  196 ,  198  of the walls  138 ,  140 ,  142 . Finally, trim pieces  168  are positioned along the side edges of panels  138 ,  170 ,  142  and  174  to finish the side edges. 
         [0041]    The panels themselves are all formed from injection molded plastic, as is the tub itself, with the integral externally threaded drainpipe. Thus, it is much less likely that the drainpipe will become loose and leak because it is molded in place and threaded onto the drain system of the recreational vehicle. Further, the injection molded plastic walls provide a continuous water barrier around three walls of the tub, preventing water from getting behind the panels to the walls of the recreational vehicle. Also, since the upper and lower walls are identical to each other, fewer molds are required and the individual molds themselves are smaller, further reducing costs. This also facilitates the easy installation of the tub enclosure with minimal labor. 
         [0042]    This has been a description of the present invention, along with the preferred method of practicing the present invention, however, the invention itself should only be defined by the appended claims wherein I CLAIM: