Abstract:
A plumbing fixture enclosure which has a bathtub or shower receptor and enclosure walls. The lower tub/receptor has an upper rim on which rests a rear wall. A side wall is pivotably connected at its upper rear to an upper front side of the rear wall and then pivots downwardly to create a horizontal watertight seal between the side and rear walls. Simultaneously, a lower retaining finger at the front bottom of the side wall catches between an insert on the upper rim and the upper rim.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    Not applicable. 
       STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    The present invention relates to plumbing enclosures which are manufactured in multiple pieces and then assembled at the site of installation (often referred to as “knockdown” type enclosures). More particularly it relates to such enclosures which can be assembled without the use of separate clamps, and largely without the use of tools. 
         [0004]    Bathtubs are sometimes designed with integral surrounding shower enclosure walls. Similarly, shower enclosures often have a receptor base/pan formed integrally with surrounding shower enclosure walls. However, the resulting enclosures can be so large that they will not fit through standard doorways or in standard elevators, thereby limiting their use with respect to the replacement market, and in any event making shipment of such products more difficult. 
         [0005]    Hence, a variety of enclosures have been developed with the tub or shower pan formed separately from the surrounding enclosure walls. The components are then assembled at the site of installation, often using separate clamps, bolts, screws and/or tools. 
         [0006]    For example, U.S. Pat. No. 2,343,201 discloses a knockdown shower enclosure with a horizontal mounting flange and three vertical walls. This design requires screws to interconnect the walls to the flange, which fasteners are time consuming to install. Further, the multitude of such fasteners complicates the installation as instructions are required illustrating the alignment of parts to be joined, what fasteners to use, etc. 
         [0007]    U.S. Pat. No. 4,384,377 discloses a tub-shower enclosure which includes back wall and side wall panels which are molded with integral interlocked portions respectively thereon. The side wall panel can be assembled with the back wall panel to provide firm engagement there between by the interengaging of the interlocked portions with each other. 
         [0008]    Specifically, a tongue portion which runs along the vertical edge of each side wall is inserted into a corresponding groove in the edge of the back wall panel. Further, dowel portions on the side walls fit within corresponding pockets in the edge of the back wall panel. This design has the disadvantage that the tongues, grooves, dowels, and pockets need to simultaneously aligned for proper assembly, which can be difficult. Additionally, it can be difficult to disassemble in the event of a repair, as the tongues and grooves have a substantially surface area in mutual contact, which surface area can become melded with calcium deposition from tap water for example, or other sediment, making them difficult to separate. 
         [0009]    See also U.S. Pat. Nos. 1,781,692, 2,282,362, 2,648,409, 4,152,789, 4,471,501, 4,457,031, 4,539,721, 4,901,380, 4,987,619, 5,263,208, 6,647,563, and 6,698,037 for other enclosure structures. 
         [0010]    Apart from issues of cost imposed by multi-part and complicated assembly features such as clamps, bolts and the like, a significant issue with such knockdown enclosures relates to insuring the watertight nature of the seams between the parts. In some cases this can require the use of caulk. In other cases this can require very close manufacturing tolerances. 
         [0011]    Hence, while a variety of multiple piece type bathing and shower enclosures are known, it is desired to develop improved knockdown plumbing fixtures. 
       SUMMARY OF THE INVENTION 
       [0012]    In one aspect the present invention provides a plumbing fixture enclosure formed of multiple pieces. The enclosure has a base having an upper rim, a first side wall mountable on the upper rim, and a second wall mountable on the upper rim abutting the first side wall. 
         [0013]    The first side wall is pivotable along an essentially horizontal axis by virtue of a pivot joint between upper edges of the first side wall and the second wall. In preferred forms the pivot joint is in the form of an upwardly open receiving pocket on one of said walls and a pivot member on the other insertable in the receiving pocket. An opposite end of the first side wall (opposite an end where the pivot joint is) is provided with a lower retainer that links to the base as the first side wall pivots relative to the second wall to an essentially horizontal position. There is an insert mounted to the upper rim which facilitates linking the retainer to the base as the first side wall pivots relative to the second wall. 
         [0014]    The insert may have a recess and projection connection with respect to the upper rim (e.g. a tang projects downward into a corresponding receiving area of the base upper rim). The tang on the insert has mounted thereon (or formed integrally therewith) a clip to facilitate frictional engagement of the tang with the receiving area of the base upper rim. The insert also has a downwardly projecting sloped ramp suitable to guide and catch a lower sloped finger portion of the retainer. 
         [0015]    The two walls have abutting structures to facilitate a serpentine recess and projection seam/joint between them when they are assembled together in facing fashion. There may also be a third wall mountable on the upper rim of the base, wherein the third wall is similarly pivotable along an essentially horizontal axis by virtue of a pivot joint between upper edges of the third and second walls. 
         [0016]    The second wall is preferably a rear enclosure wall, and the first and third walls are preferably opposed (e.g. left and right) side enclosure walls. For example, the enclosure can be a combined bathtub and shower enclosure. 
         [0017]    In another aspect the invention provides a method of assembling a plumbing fixture enclosure. One positions a bathtub on a floor or other essentially horizontal support, mounts a rear wall of a shower enclosure on an upper edge of the bathtub, links an upper edge of an enclosure side wall to an upper edge of the rear wall while the side wall is not essentially horizontal, and then pivots the side wall to an essentially horizontal position so as to thereby create an essentially watertight seam between the rear and side wall. This essentially simultaneously automatically also links a frontal lower edge of the side wall to the bathtub. 
         [0018]    It should be appreciated that by using the present invention the enclosure walls can be assembled in watertight fashion quickly, and without the use of any tools. No additional clamps on the outside of the side and rear walls are needed. Hence, there is a considerable labor and material saving. 
         [0019]    These enclosures nevertheless still serve all the primary needed functions for a knockdown enclosure. They can be manufactured in multiple parts, and thus more easily be shipped to the installation site. When it is desired to inspect or repair plumbing or other structures behind the enclosure, even long after installation, the enclosure side walls can be disassembled from the tub or shower base (by reversing the pivoting) with less risk of damaging the base or other enclosure walls. After the maintenance work, the surround can be reassembled to the base. 
         [0020]    The above-mentioned and other features and advantages of this invention will become more apparent and the invention will be better understood by reference to the following description of the preferred embodiment of the invention, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a right, upper, frontal perspective view of an enclosure of the present invention; 
           [0022]      FIG. 2  is an exploded perspective view of the enclosure of  FIG. 1 ; 
           [0023]      FIG. 3  is a perspective view of an insert that is facilitates assembly of the enclosure components; 
           [0024]      FIG. 4  is an exploded view of the  FIG. 3  insert; 
           [0025]      FIG. 5  is an end view of the  FIG. 3  insert; 
           [0026]      FIG. 6  is a side view of the  FIG. 3  insert; 
           [0027]      FIG. 7  is a fragmentary exploded perspective view illustrating assembly of a tub/shower wall joint of the enclosure; 
           [0028]      FIG. 8  is another fragmentary exploded perspective view, focusing on assembly of two adjacent shower wall portions of the enclosure near their upper ends; 
           [0029]      FIG. 9  is yet another exploded perspective view, focusing on another view of the  FIG. 7  assembly; 
           [0030]      FIG. 10  is another fragmentary exploded perspective view, focusing on assembly of two adjacent shower wall portions of the enclosure near their lower ends; 
           [0031]      FIG. 11  is a view from a right side of the enclosure, showing a right shower wall being assembled to the bathtub; 
           [0032]      FIG. 12  is a cross-sectional view taken along line  12 - 12  of  FIG. 8 , once the  FIG. 8  parts have been further assembled; 
           [0033]      FIG. 13  is a view similar to  FIG. 12 , after further relative pivoting of the parts; 
           [0034]      FIG. 14  is a cross-sectional view taken essentially along line  14 - 14  of  FIG. 10 , after the parts have been further assembled; 
           [0035]      FIG. 15  is a cross-sectional view taken along line  15 - 15  of  FIG. 10 ; 
           [0036]      FIG. 16  is a view similar to  FIG. 15 , but illustrating a further stage of assembly; 
           [0037]      FIG. 17  is a view taken along line  17 - 17  in  FIG. 9 ; 
           [0038]      FIG. 18  is a view illustrating a further stage of assembly than the  FIG. 17  illustration; 
           [0039]      FIG. 19  is a view similar to  FIG. 18 , illustrating an even further state of assembly; 
           [0040]      FIG. 20  is a view taken along section line  20 - 20  in  FIG. 19 ; and 
           [0041]      FIG. 21  is a view taken along section line  21 - 21  in  FIG. 19 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0042]    Referring first to  FIGS. 1 and 2 , there is shown a combined shower and bathtub enclosure  10  which includes a bathtub  12  having an upper rim  13 , on which is positioned a first shower enclosure side wall  14 , a shower enclosure back wall  16  (a “second wall”), and another opposed shower enclosure side wall  18  (a “third wall”). The walls  14 / 16 / 18  are joinable together to form a shower enclosure portion above the bathtub  12 . 
         [0043]    While this patent uses the term “enclosure” or “surround”, it is to be understood that such structures do not always, or even frequently, completely surround or enclose the showering/bathing areas. Instead, a door structure or a curtain, not shown, typically completes the structure. Instead, we use these terms to refer to the fixture with or without these extra final closing features. 
         [0044]    Inserts  20  and  22  are positioned on upper rim  13  to catch the frontal bottom of the opposed side walls  14  and  18 , as will be discussed below. Walls  14  and  18 , and inserts  20  and  22 , are respectively mirror images of each other. 
         [0045]    Enclosure walls  14  and  18  include a lower edge  24 . Note especially that they have a sloping retainer/finger/projection  26  at their frontal end. 
         [0046]    Turning now to  FIGS. 3-6  each insert  20 ,  22  has a tang  28  extending from a main body  30 , a flange  32  extending transversely from the main body  30 , and a second tang  34  extending transversely from the flange  32 . Main body  30  includes a ramped edge  36  extending approximately from first tang  28  past second tang  34 . 
         [0047]    Tangs  28  and  34  are inserted into respective receiving pockets  38 ,  40  at the upper edges of the bathtub. See e.g.  FIGS. 17 ,  20  and  21 . Tang  28  and tang  34  include a trapezoidal outer contour which facilitates insertion. Retaining clips  52  (each preferably with one-way barbed sides) may be mounted on the tangs to further help retain inserts  20 ,  22  in their respective receiving pockets  38 ,  40 . 
         [0048]    Referring next to  FIG. 8 , back wall  16  includes two receiving pivot pockets  42  at upper forward edges of back wall  16 . Side walls  14  and  18  include a rear upper pivot element  44 . Rear upper pivot elements  44  are designed to engage the corresponding receiving pivot pockets  42  to pivot the side walls  14  and  18  from the  FIG. 11  position to the  FIG. 12  position, and then to the  FIG. 13  position. As this occurs (to connect the upper portion of the side walls to the rear wall), the projection  26  at the lower frontal end of the side walls will interface with a corresponding ramped edge  36  ( FIGS. 17-21 ). 
         [0049]    Side walls  14  and  18  each include an approximately planar rear edge  46  approximately extending from rear upper pivot element  44  to first base edge  24  of walls  14 ,  18 . As shown in  FIG. 10 , back wall  16  has a lower edge  48  configured for adjoining bathtub  12 , and includes slots  50  approximately extending from a respective receiving pivot pocket  42  to lower edge  48 . 
         [0050]    The planar edge  46  of each side wall  14 ,  18  is inserted into a respective slot  50  when the side walls  14 ,  18  are in an assembled position with enclosure back wall  16 . See e.g.  FIGS. 15 and 16 . 
         [0051]    Note in particular that planar edges  46  (once inserted in respective slots  50 ) provides a labyrinth path which prevents water in the enclosure from leaking through the joint/seam. Additionally, the wide mouth of slot  50  allows for relatively easy insertion of edges  46  into the slots. 
         [0052]    As shown in  FIGS. 2 and 17 , edge  24  on the bottom of side wall  14  includes a ledge  54  extending transversely, and projection  26  can include a linear retainer portion  56  extending from ledge  54  at an acute angle  58 , and a curved end portion  60 . 
         [0053]    The enclosure walls  14 / 16 / 18 , and the bathtub  12 , can be formed by conventional molding techniques, preferably from plastic materials such as acrylics or fiberglass. Inserts  20  can injection molded with plastics or other materials. Retaining clip  52  may be metallic or alternatively be integrally fabricated with insert  20  during the molding or other fabrication process. 
         [0054]    When one wants to assemble the bathing/shower enclosure after the pieces have been moved to the installation site, one installs the bathtub  12  on a horizontal floor  90  or other essentially horizontal support. One then drops the back wall  16  down onto the upper rim  13  of the bathtub. One then takes a side wall ( 14  or  18 ), places its rear upper pivot element  44  into the corresponding receiving pivot pocket  42 , and pivots the side wall as shown in  FIGS. 11-13 . This creates a self-sealing joint between the side and rear wall. 
         [0055]    As this is occurring, the lower retainer  56 / 60 , as shown in  FIG. 18 , slips into the slot between ramp  36  and the upper rim  13  of the bathtub. The frictional engagement between the clips  52  and the receiving pockets  38  and  40  help the clips resist return movement out of those pockets. If the clips are securely adhered to the corresponding tangs  34  and  28 , that will also hold the inserts to the bathtub  12 . That in turn, together with gravity, will tightly hold and wedge the linear portion  56 , and thus the side wall to the top wall. The process is then repeated for the other side wall  18 . 
         [0056]    This all occurs without the need for any clamps or screws, and if maintenance access to the area behind the enclosure is ever needed the process can be reversed. Importantly, this is achieved without the need for caulk to assure watertight seams. 
         [0057]    While a preferred embodiment of the invention has been disclosed, other modifications and variations will be apparent to those skilled in the art, which are intended to be within the spirit and scope of the invention. For example, while the invention has been depicted in the context of a combined bathtub/shower enclosure, it could also be used for a combined shower receptor and surrounding walls, or a combined sauna and wall surround. 
         [0058]    Therefore, the present invention is not intended to be limited to just the described most preferred embodiments. To ascertain the full scope of the invention, the claims which follow should be referenced. 
       INDUSTRIAL APPLICABILITY 
       [0059]    The invention provides multi-part plumbing fixture enclosures which can be easily assembled at the site of installation.