Abstract:
The system for installing shower walls includes a pressure transfer member for urging a shower wall against a back up support during bonding of the shower wall to the support. An adjustable force development device engages the pressure transfer member to force the pressure transfer member against the shower wall. A support member engages the pressure transfer member when the force development device exerts a predetermined force against the shower wall. A fixation device holds the support member to maintain the pressure transfer position of the pressure transfer member. The fixation device includes a cam that moves a shower wall into a tight corner fit with an adjacent shower wall.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to systems and methods for building shower enclosures, and more particularly to a system and method for installing shower walls in a shower enclosure. 
     Shower enclosures are usually set up and installed by professionals, especially when the shower walls for such enclosures are formed of a one-piece material such as natural or artificial stone. Stone shower walls generally require custom sizing, and skilled handling for installation in a shower enclosure. The expenses and complexity of such installation may discourage a do-it-yourselfer from using stone or other similar unitary wall structures in shower enclosures. 
     As used herein the term “shower enclosure” is intended to refer to a shower chamber or shower stall with two or more shower walls, and is closable by a shower door, and can also include one or more fixed glass or plastic panels that extend away from the shower walls to the shower door. 
     In accordance with the invention unitary shower wall structures (also referred to as shower walls) can be made in predetermined sizes and packaged individually or in a kit. The invention also includes novel installation tools that enable a do-it-yourselfer to install the shower walls. Thus the present system for installing shower walls is amenable for mass marketing as one or more off-the-shelf products. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       In the accompanying drawings, 
         FIG. 1A  to  FIG. 1X  are simplified pictorial diagrams showing the development of a shower enclosure and the installation of shower walls in the shower enclosure using the system for installing shower walls; 
         FIG. 2  is a simplified plan view showing one embodiment of the system for installing shower walls, for a three wall shower enclosure; 
         FIG. 3  is a simplified plan view of another embodiment of the system for installing shower walls, for a two wall shower enclosure; 
         FIG. 4  is an enlarged perspective view of the system of  FIG. 2  with the backup support walls of the shower enclosure being generally omitted for purposes of clarity; 
         FIG. 5  is an enlarged perspective front view of a cam tool and holding device for the system, positioned against an edge of one of the shower walls; 
         FIG. 6  is an enlarged perspective rear view of the cam tool and holding device of  FIG. 4 ; 
         FIG. 7  is an enlarged perspective view of an adjustable force development device for the system, including a crank assembly; 
         FIG. 8  is an exploded view of the crank assembly of  FIG. 7 . 
         FIG. 9  is a perspective view of one pressure transfer member of the system; 
         FIG. 10  is a perspective view of another pressure transfer member of the system; 
         FIG. 11  is a rear view of the cam tool and holding device of  FIG. 6 , showing the cam head in contact with the cam follower, and the molded ribs of  FIG. 6  being omitted for purposes of clarity; 
         FIG. 12  is an auxiliary view of the cam tool and holding device taken on the line  12 - 12  of  FIG. 11 ; and, 
         FIG. 13  is a view similar to  FIG. 11  showing another position of the cam head relative to the cam follower; 
     
    
    
     Corresponding reference numbers indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     One embodiment of a system for installing shower walls in a three-wall shower enclosure is generally indicated by the reference number  10  in  FIG. 2 . The three-wall shower enclosure is generally indicated by the reference number  12 , and includes sidewalls  16 ,  18  and a rear wall  20 . 
     The development of a three-wall shower enclosure is shown in simplified pictorial fashion in  FIGS. 1A to 1H . 
       FIG. 1A  to  FIG. 1F  show a preferred structural framework for a three wall shower enclosure. 
       FIGS. 1G to 1H  show the installation of backup support walls for the shower walls, and a shower floor tray with a drain for the shower enclosure. 
       FIGS. 1I to 1M  show a bonding material being provided on the front of the backup support walls for securement of the shower walls on the backup support walls. 
       FIGS. 1M to 1U  show the shower walls in their initial placement position against the backup support walls. 
       FIGS. 1N to 1U  show the system for holding or installing the shower walls in a desired securement position against the backup support walls in the shower enclosure until a bonding material for the shower walls dries and cures. 
       FIGS. 1V to 1X  show finishing operations for the shower walls after the shower walls are sufficiently secured in the shower enclosure. 
     It should be noted that any structural dimensions and bonding material cure times indicated in  FIG. 1A  to  FIG. 1X  are for example, and are not intended to exclude other feasible dimensions or cure times. 
     Each shower wall is preferably a laminate of a natural or synthetic stone material such as granite or marble, or a synthetic stone-like material bonded to a backup support layer. The stone or stone-like layer can be approximately 4 mm thick, for example. A suitable bonding adhesive is a combination of Magpow Aluminum Honeycomb Compound Glues 1693A, 1693B, 1693-1(A) and 1693-1(B). 
     The backup layer for the stone or synthetic stone layer is preferably formed of a flexible PVC material that is fluted at its rear surface. The fluting can be accomplished with a BF2010022 die. The fluted surface provides the backup layer with a desired yieldability under pressure. Such yieldability helps ensure a secure bond between the shower walls and the backup support walls in the shower enclosure. 
     Referring to  FIG. 2  of the drawings, the system  10  for installing the shower walls is used to press against and hold in a desired securement position the side shower walls  16 ,  18  and the rear shower wall  20  ( FIGS. 2 and 3 ) of the shower enclosure  12 , until a bonding material (FIGS.  1 H,  1 L and  1 M) for the shower walls  16 ,  18  and  20  dries or cures to create a secure bond. 
     As shown in  FIG. 1U  one shower wall installation system, identified by the reference number  10  in  FIGS. 2 and 4 , can be used at an upper portion of the shower walls and a second shower wall installation system  10  can be used at a lower portion of the shower walls. 
     The system  10  ( FIGS. 2 and 4 ) includes pressure transfer members  26  and  28  for the side shower walls  16  and  18 , and a pressure transfer member  30  for the rear shower wall  20 . Pressure is applied to the pressure transfer members  26 ,  28  and  30  by adjustable force development devices  36  and  38  ( FIG. 2 ) which engage the pressure transfer members  26 ,  28  and  30 . 
     The system  10  ( FIGS. 2 and 4 ) further includes support members in the form of elongated struts or pipes  44 ,  46  which can be formed of any suitable material such as 1½ inch diameter plastic tube, which respectively engage the pressure transfer members  26  and  28 . 
     The system  10  also includes a combination cam tool and holding device  52  ( FIGS. 2 and 4 ) that engages the support member  44  and an edge  48  of the sidewall  16 . 
     The system  10  further includes an identical cam tool and holding device  54  ( FIGS. 2 and 4 ) that engages the support member  46  and an edge  58  of the sidewall  18 . 
     The pressure transfer members  26  and  28  ( FIG. 9 ) include a base portion  64  having a pressure transfer surface  66  ( FIG. 4 ) that is directed against the respective shower walls  16  and  18  ( FIGS. 2 and 4 ). The pressure transfer members  26  and  28  ( FIG. 9 ) also include engagement arms  72  and  74  that have an intersection angle A of approximately 135°, although other angles are also feasible. 
     The arms  72  and  74  ( FIG. 9 ) have upper and lower fins  80 ,  82 ,  84 ,  86  and  88  that extend upwardly and downwardly from a shelf  90 . The fins  82 ,  82 ,  84 ,  86  and  88  provide the arms  72  and  74  with strength, rigidity and lightness of weight. 
     The fins  80  and  88  ( FIG. 9 ) have contact surfaces  94  and the fins  82 ,  84  and  86  have opposite contact edges  96 ,  98  and  100 . The contact surfaces  94  and the contact edges  96 ,  98  and  100  are elements or segments of an imaginary cylindrical surface. 
     The arms  72  and  74  ( FIG. 9 ) project from spaced sidewalls  102  and  104  that extend from the base portion  64  and are joined by ribs  110 ,  112  and  114 . The pressure transfer members  26  and  28  are preferably molded from a suitable known plastic. 
     The pressure transfer member  30  ( FIG. 10 ) includes a base portion  120  having a pressure transfer surface  122  that is directed against the rear shower wall  20  ( FIG. 4 ). The pressure transfer member  30  also includes engagement arms  128  and  130  that have an intersection angle B of approximately 90°, although other angles are also feasible. 
     The engagement arms  128  and  130  are finned in the same manner as the arms  72  and  74  of the pressure transfer members  26  and  28 , and are thus identified by corresponding reference numbers. 
     The arms  128  and  130  ( FIG. 10 ) project from spaced sidewalls  136  and  138  that extend from the base portion  120 . The sidewalls  136  and  138  are joined by ribs  144 ,  146  and  148  that also intersect a median wall  154  that extends from the base portion  120 . As with the pressure transfer members  26  and  28  the pressure transfer member  30  is preferably molded from a suitable known plastic material. 
     The adjustable force development device  36  ( FIGS. 2 ,  4  and  7 ), which is identical to the force development device  38 , includes a threaded jack assembly or threaded Tommy bar assembly  162  cooperable with a pair of elongated struts  164  and  166  ( FIGS. 4 and 7 ). 
     As shown in  FIGS. 7 and 8 , the jack assembly  162  includes a hollow crank member  172  having a central hub portion  174  with a turn handle  176 . The hub portion  174  has a projecting end  180  ( FIG. 8 ) of reduced diameter. The crank member  172  is provided with internal threads  182 . 
     The projecting end  180  fits into an end  188  ( FIGS. 4 and 7 ) of the strut  164  for relative turning movement with respect to the strut  164  via the turn handle  176 . 
     The jack assembly  162  also includes a hollow externally threaded member  196  ( FIGS. 7 and 8 ) having a strut engaging end  198  ( FIG. 8 ) that fits tightly or is locked into a confronting open end  204  of the strut  166 . The tight fit or lock fit prevents relative movement of the externally threaded member  196  with respect to the strut  166 . 
     The externally threaded member  196  has a threaded portion  206  on a reduced diameter section  208  that extends away from the strut engaging end  198 . A peripheral bead  210  that limits insertion of the threaded member  196  into the strut  166  is formed on the strut engaging end  198  where it intersects the reduced diameter section  208 . The threaded portion  206  is engageable with the internal threads  182  of the rotatable crank member  172  as shown in  FIG. 7 . 
     Under this arrangement, rotation of the turn handle  176  of the jack assembly  162  ( FIG. 8 ) causes threaded movement of the crank member  172  relative to the nonturnable threaded member  196 , to provide a desired spacing between the confronting ends  188  and  204  ( FIGS. 4 and 7 ) of the struts  164  and  166 . 
     An opposite force transmitting end  214  of the strut  164  ( FIGS. 4 and 8 ) engages the pressure transfer member  26  at the arm  74  ( FIG. 9 ). An opposite force transmitting end  216  ( FIGS. 2 and 8 ) of the strut  166  ( FIGS. 4 and 7 ) engages the pressure transfer member  30  at the arm  128  ( FIG. 10 ). 
     The struts  164  and  166  can be formed of any suitable material such as 1½ inch diameter plastic tube. 
     The force development device  38  includes a threaded crank assembly  220 , identical to the crank assembly  162 , cooperable with a pair of elongated struts  222  and  224 , ( FIG. 4 ) identical to the struts  164  and  166 . The force development device  38  is assembled and operates in a manner similar to that previously described for the force development device  36 . 
     Thus, an end  230  ( FIG. 4 ) of the strut  222  engages the crank member  172  of the jack assembly  220 . A confronting end  232  of the strut  224  ( FIG. 4 ) engages the externally threaded member  196  of the jack assembly  220 . Under this arrangement turning movement of the turn handle  176  provides a desired spacing between the confronting ends  230  and  232  of the struts  222  and  224 . 
     An opposite force transmitting end  238  ( FIG. 4 ) of the strut  222  engages the pressure transfer member  30  at the arm  130  ( FIG. 10 ). An opposite force transmitting end  240  of the strut  224  engages the pressure transfer member  28  ( FIG. 4 ) at the arm  72  ( FIG. 9 ). Thus turning of the turn handle  176  of the jack assembly  220  provides a desired spacing between the confronting ends  230  and  232  of the struts  222  and  224 . 
     The elongated support member  44  has an end  246  ( FIG. 4 ) that engages the pressure transfer member  26  at the arm  72  ( FIG. 9 ). An opposite end  248  of the support member  44  engages the cam tool and holding device  52 . 
     Similarly, the elongated support member  46  has an end  254  ( FIG. 4 ) that engages the pressure transfer member  28  at the arm  72  ( FIG. 9 ). An opposite end  256  of the support member  46  engages the cam tool and holding device  54 . 
     The cam tool and holding device  52  ( FIG. 4 ) includes a base  262  with opposite peripheral ear portions  266  and  268  ( FIGS. 5 ,  6 ,  11  and  13 . A fastener opening  274  ( FIG. 11 ) is provided in each ear portion  262  and  268  for reception of a fastener  276  ( FIG. 5 ) for securing the base to a backup support wall  348  next to the edge  48  of the shower wall  16 . Such securement establishes the fixation position of the device  52 . 
     A support stub  284  ( FIGS. 5 and 13 ) is formed on or joined to a top surface  290  ( FIG. 5 ) of the base  262  and extends beyond a peripheral edge  292  ( FIGS. 5 and 13 ) of the base  262 . The support stub  284  is engageable with the end  248  of the support member  44  ( FIGS. 2 ,  4  and  5 ) for supporting the end  248  in a position that is determined by the fixation position of the device  52 . 
     The device  52  thus holds the support member  44  in its support position, wherein the support member  44  engages the pressure transfer member  26  ( FIGS. 2 and 4 ) to maintain the pressure transfer member  26  in a desired pressure transfer position against the shower wall  16 . 
     The cam tool and holding device  54 , which is identical to the cam tool and holding device  52 , is secured to a backup support wall  350  ( FIG. 2 ) next to the edge  58  of the shower wall  18 , to establish the fixation position of the device  54 . 
     The device  54  also includes a support stub  284  that engages the end  256  ( FIGS. 2 and 4 ) of the support member  46  when the device  54  is fixed in position on the support wall  350 . The device  54  thus supports the end  256  of the support member  46  in a position that is determined by the fixation position of the device  54 . 
     The device  54  therefore holds the support member  46  in a support position, wherein the support member  46  engages the pressure transfer member  28  ( FIGS. 2 and 4 ) to maintain the pressure transfer member  28  in a desired pressure transfer position against the shower wall  18 . 
     The cam tool and holding device  52  further includes a cam  300  and a cam follower  306 . The cam  300  has a cam head  308  that is rotatable on a hub portion  314  that projects from a bottom surface  316  of the base  262 , and is integral with the base  262 . 
     The hub portion  314  is formed with an opening  318  ( FIGS. 11-13 ) for a fastener  276  ( FIG. 5 ). 
     A cam lever arm  322  ( FIGS. 5 and 6 ) extends from the cam head  308 . The cam head  308  has a cam surface  324  ( FIGS. 6 ,  11  and  13 ) engageable with a cam engagement surface  326  on the cam follower  306 . 
     The cam surface  324  or the cam engagement surface  326  can be provided with faceting (not shown) to reduce slippage between the surfaces  324  and  326  when engagement occurs. 
     The cam follower  306  has a driving surface  332  ( FIGS. 11 and 13 ) opposite the cam engagement surface  326 . The driving surface  332  ( FIGS. 11-13 ) is engageable with the edge  48  ( FIGS. 5 and 6 ) of the shower wall  16 . 
     The cam follower  306  also includes flexible end straps  334  and  336  ( FIGS. 5 ,  6  and  11 - 13 ) respectively joined to the ear portions  266  and  268  of the base  262  to permit movement of the cam follower  306  with respect to the base  262 . The cam follower  306 , the straps  334 ,  336 , the base  262  and the ear portions  266  and  268  can be molded as a one-piece structure. 
     The cam follower further includes a surface contacting portion  342  for contacting the exposed surface of the shower wall  16  ( FIGS. 5 ,  11  and  13 ). 
     The cam tool and holding device  54  also includes a cam  300  rotatably mounted on a hub  314 , and a cam follower  306 , as previously described for the cam tool and holding device  52 . 
     During installation of the shower walls  16 ,  18  and  20  the walls  16 ,  18  and  20  are positioned in the shower wall enclosure  12  in a manner generally indicated in the  FIGS. 1H to 1P . The shower walls  16 ,  18  and  20  are thus placed against the backup support walls  348 ,  350  and  352  ( FIG. 2A ), which are provided with a bonding material. 
     The bonding material will ultimately form a permanent bond between the shower walls  16 ,  18  and  20 , and their backup support walls  348 ,  350  and  352 . 
     However, to ensure adequate surface contact between the shower walls  16 ,  18  and  20 , and their respective backup support walls  348 ,  350  and  352 , it is desirable to apply pressure on the shower walls  16 ,  18  and  20  while the bonding material cures. 
     The system  10  provides the desirable pressure on the shower walls  16 ,  18  and  20  during the curing period of the bonding material. 
     However, before the entire system  10  is placed in the position of  FIGS. 2 and 3 , the cam tool and holding devices  52  and  54  are first installed. The devices  52  and  54  are initially used to slide the side shower walls  16 ,  18  against the rear shower wall  20 . Thus when the bonding material cures a tight joint will be provided at the corners C and D ( FIG. 2 ) between the side shower walls  16 ,  18  and the rear shower wall  20 . 
     The cam tool and holding device  52  and  54  are thus affixed alongside the edges  48  and  58  of the shower walls  16  and  18  ( FIGS. 2 and 4 ) in the manner indicated in  FIG. 1R . If two sets of the system  10  are to be used, two cam tools and holding devices  52  are provided at the edge  48  of the shower wall  16  and two cam tools and holding devices  54  are provided at the edge  58  of the of the shower  18  in a manner similar to that indicated in  FIG. 1X . 
     The cam tool and holding devices  52  and  54  are located relative to the edges  48  and  58  of the shower walls  16  and  18  such that the driving surface  332  of the cam follower  306  contacts the edges  48  and  58  of the shower walls  16  and  18  while a portion  356  ( FIG. 13 ) of the cam surface  324  having the smallest radial distance from the cam pivot axis  358  ( FIG. 12 ) at the center of the fastener opening  318  is arranged to contact the cam engagement surface  326  of the cam follower  306 . 
     Under this arrangement rotation of the handle  322  of the cam  300  will cause the cam surface  324  to forcibly engage the cam engagement surface  326  on the cam follower  306 . The force exerted by the cam surface  326  on the cam follower  306  is transferred to the driving surface  332  of the cam follower  306  that engages the edge  48  of the side wall  16 , for example. Such force will urge the side wall  16  to slide toward the rear wall  20  thereby creating a tight corner engagement at the corner C between the wall  16  and the wall  20 . 
     A similar operation is provided with the cam tool and holding tool  54  to cause the side shower wall  18  to slide toward the rear shower wall  20  thereby creating a tight corner joint at corner D between the wall  18  and the wall  20 . 
     Once the tight corner joints have been established at the corners C and D ( FIGS. 2 and 3 ) the other components of the system  10  in addition to the earn tool and holding devices  52  and  54  are put in place as shown in  FIG. 3 . 
     Thus the pressure transfer members  26 ,  28  and  30  are engaged with the adjustable force development means  36  and  38 . The support members  44  and  46  are engaged with the pressure transfer members  26  and  28  as shown in  FIGS. 2 and 3 . The crank devices  36  and  38  of the force development devices are in a relatively light force development condition to facilitate location of the pressure transfer members  26 ,  28  and  30  on the shower walls  16 ,  18  and  20  in a desired pressure transfer position. 
     It will be noted that the cam tool and holding devices  52  and  54  in their previously affixed positions, dictate the height at which the system  10  is positioned in the shower enclosure  12 . 
     Referring to  FIGS. 2 and 4  with the system  10  thus positioned the crank devices  36  and  38  are rotated in a counterclockwise direction, for example, to spread the confronting ends of the struts  164  and  166  and thereby impose a force on the pressure transfer members  26  and  30  via the struts  164  and  166 . 
     Similarly counterclockwise rotation of the crank member  220  of the force development device  38  will spread the confronting ends  230  and  232  of the struts  222  and  224  to impose a force on the pressure transfer members  28  and  30  via the struts  222  and  224 . 
     The pressure transfer members  26  and  28  are held in position by the support members  44  and  46  and the pressure transfer member  30  is held in position, by a combination of the force imposed thereon by the force development devices  36  and  38  and the stabilization of the pressure transfer members  26  and  28  by the support members  44  and  46  and the devices  52  and  54 . 
     The devices  52  and  54  hold the support members  44  and  46  in their respective support positions and ultimately maintain the pressure transfer members  26 ,  28  and  30  in their respective pressure transfer positions. 
     The affixation of the devices  52  and  54  alongside the shower walls  16  and  18  ensures stability of the system  10  during the installation of the shower walls  16 ,  18  and  20 . 
     After a desirable cure period for the bonding material has elapsed, such as for example 24 hours, the system  10  can be removed from the shower walls  16 ,  18  and  20  by reducing the force imposed by the force development devices  36  and  38 , disengaging the force development devices  36 ,  38  from the respective pressure transfer members  26 ,  28  and  30  and removing the support struts  44  and  46  from the devices  52  and  54 . The devices  52  and  54  can then be detached from their affixed position alongside the edges  48  and  58  of the shower walls  16  and  18 . 
     In another embodiment of the invention a system for installing shower walls in a two wall shower enclosure is generally indicated by the reference number  370  in  FIG. 3 . The two wall shower enclosure is generally indicated by the reference number  372 , and includes shower walls  378  and  380 . The shower walls  378  and  380  intersect at a corner angle E of approximately 90°, although other intersection angles are also feasible. 
     The system  370  ( FIG. 3 ) includes the pressure transfer members  26  and  28  for the shower walls  378  and  380 . Pressure is applied to the pressure transfer members  26  and  28  by the adjustable force development  36  ( FIGS. 7 and 8 ) which engage the pressure transfer members  26  and  28 . 
     The system  370  ( FIG. 3 ) further includes the support members  44  and  46  which respectively engage the pressure transfer members  26  and  28 . 
     The system  370  also includes the combination cam tool and holding devices  52  and  54  ( FIGS. 5-13 ) that engage the support members  44  and  46 . 
     The cam tool and holding devices  52  and  54  also engage edges  386  and  388  of the shower walls in a manner similar to that described for the system  10  engagement of the shower wall edges  44  and  58  by the devices  52  and  54 . 
     The system  370  is operated in a manner similar to that previously described for the system  10 . Thus the force development device  36  is operated to increase the space or distance between the confronting ends  188  and  204  of the struts  164  and  166  to impose a force on the pressure on the pressure transfer members  26  and  28  as previously described for the system  10 . 
     The forces exerted on the pressure transfer members  26  and  28  are applied against the shower walls  378  and  380  after they have been shifted into a tight corner joint by the cam tool and holding devices  52  and  54  in a manner similar to that previously described for the system  10 . 
     Thus the system  370  presses against and maintains the shower walls  378  and  380  in a desired securement position against backup support walls  394  and  396  until a bonding material for the shower walls dries and cures. 
     As various changes can be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a liming sense.