Abstract:
The present invention relates a novel adaptor to position tiles or tile-like elements within or around a bathing apparatus, or both. The present invention further includes a method of using the tile adaptor for the installation of tiles. In a representative embodiment, the tile adaptor includes one or more flanges along at least one of its sides to allow the installation of tiles of a variety of thicknesses at a number of places. The adaptor is integrated in the final bathing apparatus. One or more adaptors may be positioned on the floor, wall and/or ceiling of the bathing apparatus, depending on the design of the bathing enclosure. Advantageously, the tile adaptor is easy to install and to use, and it may conveniently be manufactured from a lightweight material such as extruded plastic or a synthetic polymer.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present patent application claims the priority of U.S. Provisional Patent Application No. 61/100,506 which was filed on Sep. 26, 2008 and which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
       [0002]    The present invention relates a novel adaptor to position tiles or tile-like elements. More specifically, the invention concerns a novel adaptor for positioning tiles within and/or around bathing apparatus, such as bathtubs and showers, and includes a method for using this adaptor. 
         [0003]    Pre-fabricated bathing apparatus, such as showers and bathtubs, are frequently manufactured in components that are to be assembled on site. For reasons of transportation, size and installation, this is often necessary. Ideally, once on site, the assembly process should be easy and fast to minimize costs. 
         [0004]    Generally, a modern bathing apparatus comprises a base unit and wall units that must be attached to one another as well as to the structure of the building in which it is housed. This attachment must be done in a way that will prevent water leakage and that will not cause the building to deteriorate. 
         [0005]    Tiles may be positioned within or outside the bathing apparatus, or both. Prior to the introduction of pre-fabricated bathing apparatus, tiles were routinely used in the construction of bath and shower units, and they have never fallen out of favor with consumers. Today, tiles may be chosen either as an alternative to pre-fabricated bathing units or to complete pre-fabricated units. There are a number of reasons for this. Some individuals prefer the feel of tile to the synthetic polymers that are used in pre-fabricated bathing apparatus. The infinite variety of tile styles and materials, both man-made and natural, allows for innovative design opportunities. Tiles will therefore continue to be an important element in the construction of showers and bathtubs for the foreseeable future. 
         [0006]    Unfortunately, placing tiles within or around a bathing apparatus evenly can be a tricky endeavor. Skill is required to ensure that the tiles are properly aligned, especially when the bathing apparatus is not entirely level. Blocks of wood and other elements must sometimes be used to compensate for the lack of a perfectly flush surface, whether this is the case for the floor or wall of the bathing apparatus. 
         [0007]    Devices or tools that can be of assistance for the installation of tile are not common. U.S. Pat. No. 5,832,619 (Volkema, Jr.) describes an adjustable installation tool in the shape of a frame for simultaneously aligning and installing multiple tiles. While helpful in many instances, the use of such a frame may not be possible in small enclosures or in certain areas of a bathtub or shower enclosure. 
         [0008]    U.S. Pat. No. 7,536,802 (Tavy et al.) teaches a tile-spacing device for spacing tiles apart from one another during their installation. The device is characterized by having a window that extends through the base, through which engagement of at least one of the tiles with the edge of a spacer can be visually observed. Once again, a device of this type may not be suitable for installing tiles in certain types of bathing enclosures. 
         [0009]    The Tile Redi corporation has developed a number of prefabricated shower modules that are useful for constructing tiled shower enclosures: see, for example, U.S. Patent Publications Nos. US2008/0222891A1, US2008/0222797A1, US2008/0222796A1, US2008/0222795A1, US2008/0222794A1 and US2008/0222793A1 and U.S. Pat. No. 5,913,777. While these modules are helpful for the installation of shower tile, they are also somewhat limiting as the tiles are necessarily installed within the confines of these modules. 
         [0010]    There thus remains a need for a device and/or method to facilitate the positioning of tile or tile-like elements during the construction of a bathing apparatus, such as bathtub or shower. Ideally, such a device would allow a great variety of design options and be of assistance for the installation of floor, wall and ceiling tile in a bathing enclosure. 
         [0011]    The present invention seeks to meet these and related needs. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention provides a novel adaptor that facilitates the positioning of tiles or tile-like elements in and/or around a bathing apparatus, such as a bathtub or shower. The adaptor becomes an integral part of the final bathing apparatus and is designed to be used with pre-existing prefabricated bathing components, such as those found in modern day showers and bathtubs. 
         [0013]    The adaptor is sturdy and watertight, as required for use in applications such as the assembly of pre-fabricated bathing components found in modern day shower and bathtub installations. In a representative embodiment, the adaptor is made of extruded plastic, but it may also be manufactured from other synthetic polymers, such as polyvinyl chloride, acrylonitrile-butadiene-styrene tripolymer, acrylic, polyurethane, fiberglass with gel coat, cast polymer, stainless steel, painted steel or aluminum, amongst other materials that are known in the art of bathtub and shower manufacturing. 
         [0014]    As will be described in further detail below, the tile adaptor of the present invention is characterized by having one or more flanges along at least one of its sides. This allows the installation of tiles at different levels, or tiles having a variety of thicknesses, in a way that is simpler and easier than has hitherto been possible. The flanges serve as a guide for the positioning of the tiles within or around the bathing apparatus, as will be described more particularly below. 
         [0015]    The invention includes several embodiments for specific use on the floor, wall and/or ceiling of a bathing apparatus. 
         [0016]    Advantageously, the adaptor is simple to install. When utilized in the assembly of a bathing apparatus, for example, the intervention of a plumbing professional is not necessarily required. In addition, the inclusion of one or more adaptors in an assembly does not interfere with the application of sealant between parts of the bathing apparatus. 
         [0017]    Other objects, advantages and features of the present invention will become apparent upon reading of the following non-restrictive description of embodiments thereof, given by way of example only with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of a first representative embodiment of a tile adaptor of the present invention that is suitable for the installation of wall tile; 
           [0019]      FIG. 2  is a perspective view of a second representative embodiment of a tile adaptor of the present invention that is suitable for the installation of wall tile; 
           [0020]      FIG. 3  is a perspective view of a variation of the embodiment of the tile adaptor shown in  FIG. 2 ; 
           [0021]      FIG. 4  is a perspective view of a slightly different variation of the tile adaptor shown in either  FIG. 3 ; 
           [0022]      FIG. 5  is a perspective view of a yet another variation of the embodiment of the tile adaptor shown in  FIG. 3 ; 
           [0023]      FIG. 6  is a perspective view of a further alternative embodiment of the tile adaptor shown in  FIGS. 1 and 2 ; 
           [0024]      FIG. 7  is a perspective view of the embodiment of the tile adaptor shown in  FIG. 6  while in use; 
           [0025]      FIG. 8  is a perspective view of a slight variation of the embodiment of the tile adaptor shown in  FIGS. 6 and 7 ; 
           [0026]      FIG. 9  is a perspective view of the wall tile adaptor shown in  FIG. 6  used in conjunction with the floor tile adaptor shown in  FIG. 13 ; illustrating the installation of tiles on one of the walls of a bathing apparatus as well as floor tiles inside and outside of the bathing apparatus; 
           [0027]      FIG. 10  is a perspective view of the wall tile adaptor shown in  FIG. 8  used in conjunction with the tile adaptor shown in  FIG. 13 , illustrating the installation of tiles on one of the walls of a bathing apparatus as well as floor tiles inside and outside of the bathing apparatus; 
           [0028]      FIG. 11  is a perspective view of a representative embodiment of a floor tile adaptor of the present invention that is suitable for the installation of floor tile; 
           [0029]      FIG. 12  is an alternative embodiment of the floor tile adaptor of  FIG. 11 ; 
           [0030]      FIG. 13  is a perspective view of the floor tile adaptor shown in  FIG. 12  shown in its entirety and while in use; 
           [0031]      FIG. 14  is a cutaway view of the floor tile adaptor shown in  FIG. 12 ; 
           [0032]      FIG. 15  is a right side perspective view of the tile adaptor shown in  FIG. 11  while in use to install both floor and wall tiles; 
           [0033]      FIG. 16  is a left side perspective view of the tile adaptor shown in  FIG. 15 ; 
           [0034]      FIG. 17  is a perspective view of floor tile adaptor  50 A shown in  FIG. 13  used in conjunction with wall tile adaptor  10 E shown in  FIG. 6 ; 
           [0035]      FIG. 18  is a perspective view of floor tile adaptor  50 A shown in  FIG. 13  used in conjunction with wall tile adaptor  10 D shown in  FIG. 5 ; 
           [0036]      FIG. 19  is a perspective view of a second alternative embodiment of floor tile adaptor  50  shown in  FIG. 11 ,  50 B, illustrating the installation of floor tiles both inside and outside of the bathing apparatus; 
           [0037]      FIG. 20  is an enlarged view of floor tile adaptor  50 B shown in  FIG. 19 ; 
           [0038]      FIG. 21  is a perspective view of a third alternative embodiment variation of floor tile adaptor  50  shown in  FIG. 11 ,  50 C, illustrating the installation of floor tiles both inside and outside of the bathing apparatus; 
           [0039]      FIG. 22  is a perspective view of a variation of the tile adaptor shown in  FIG. 11 , wherein the adaptor is attached to a tray element to create a bathing pan; 
           [0040]      FIG. 23  is a cutaway assembled view of the tile adaptor shown in  22  taken along lines P-P′; 
           [0041]      FIG. 24  is a left side perspective view of the tile adaptor shown in  FIG. 23 , illustrating the actual installation of tiles; 
           [0042]      FIG. 25  is right side perspective view of the tile adaptor shown in  FIG. 24 ; 
           [0043]      FIG. 26  is a close-up alternative view of the tile adaptor shown in  FIG. 24 . 
           [0044]      FIG. 27  is a front perspective view of a wall tile adaptor  10 C shown in  FIG. 4  in conjunction with floor tile adaptor  50 B shown in  FIG. 19  and further including a ceiling tile adaptor; 
           [0045]      FIG. 28  is a left side perspective view of the tile adaptor combination shown in  FIG. 27 ; and 
           [0046]      FIG. 29  is a right side perspective view of the tile adaptor combination shown in  FIG. 27 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0047]    As used herein, the term “tile” or “tile-like element” means a generally flat and thin slab, frequently rectangular or square in shape, though not necessarily so (i.e., other geometrical shapes are used to make tiles, including hexagons, for example). Tiles may be made from any material and the present invention contemplates use of all of them. While tiles are very often made from ceramic and have a hard glaze finish, other materials are also used, including glass, marble, granite, slate, rubber and reformed ceramic slurry, which is cased in a mold and fired. 
         [0048]      FIG. 1  shows a first embodiment of a tile adaptor in accordance with the present invention that is suitable for installing wall tile. The adaptor is generally designated by the numeral  10 . In this embodiment, the adaptor has a generally rectangular appearance, with its top and bottom ends thereof being of a shorter length than its sides. One or both of the sides of the adaptor  10  is comprised of one or a plurality of ridges or flanges  15  which serve to align tiles  2  in an even and predictable manner. As may be seen in  FIG. 1 , the adaptor is attached at the periphery of the bathing enclosure  100  between one of the enclosure&#39;s interior walls  30  and exterior wall  32  (here shown with baseboard  37 ) against a vertical wall support element  36 . In most cases, the attachment will be made using permanent fixation means. In this case, the bathing apparatus is a bathtub  20  and includes a base  25  with a drain element  27 . 
         [0049]      FIG. 2  illustrates a variant  10 A of the tile adaptor  10  shown in  FIG. 1 . In this embodiment, the tile adaptor  10 A is broader and includes a splash guard  16 . The adaptor  10 A further includes one or a plurality of ridges or flanges  15  which serve to align tiles both within and outside of the bathing enclosure  100 . 
         [0050]      FIG. 3  shows a variant  10 B of the tile adaptor  10  represented in  FIG. 1 . Like the other tile adaptors, version  10 B includes one or a plurality of ridges or flanges  15  which serve to align tiles within the interior and/or the exterior of the bathing enclosure  100 . In this version, the tile adaptor is positioned within the bathing enclosure  100  in a permanent fashion. The front portion of the adaptor  10 B may serve as a wall unit only, or it may be prefabricated with all the plumbing features needed to operate a shower. In the latter case, a shower control  22  (not shown in this figure) may be installed at or in the general vicinity of element  17 . Similarly, a shower head  24  (not shown in this figure) may be placed at or near element  18 . The tile adaptor  10 B may optionally include a sconce  19  or analogous feature, such as a shelf, to store toiletries. 
         [0051]      FIG. 4  shows a variation of the tile adaptor illustrated in  FIG. 3 . Once again, the tile adaptor  10 C includes one or a plurality of ridges or flanges  15  which serve to align tiles within the interior and/or the exterior of the bathing enclosure  100 . In this variation, the tile adaptor  10 C includes an opening for a shower control  22  but not for a shower head  24 . A sconce  19  is provided to place personal care items. As shown in this figure, the tile adaptor  10 C guides the installation of tiles  2  on the wall  30 . Vertical and horizontal construction elements  36  and  38  serve to support the wall  30  of the bathing enclosure  100 . 
         [0052]      FIG. 5  shows a tile adaptor  10 D that is very similar to the tile adaptor  10 C illustrated in  FIG. 4 . This version includes two additional features: an opening for a shower head  24 , and means  42  to attach a shower curtain  46  via a pole  44 , or other element suitable for suspending the curtain  46 . 
         [0053]      FIG. 6  illustrates a further alternative to the adaptor shown in  FIG. 2 . In this version, the tile adaptor  10 E is characterized by having an extended sconce  19 A that runs through nearly the entire length of the adaptor. The dimensions of the extended sconce  19 A may be modified, or the extended sconce  19 A may be replaced by a plurality of sconces  19  or their equivalent. The ridge(s) or flange(s)  15  that are characteristic of all embodiments of the tile adaptor  10  are visible from  FIG. 6 . 
         [0054]      FIG. 7  shows the tile adaptor  10 E in use. The ridges or flanges  15  of the tile adaptor  10 E serve to align the tiles  2  on the wall  30 . The wall  30  of the enclosure  100  is supported by one or more wall support elements  36 , while the floor of the enclosure (not shown) is supported by one or more horizontal floor support elements  38 . 
         [0055]      FIG. 8  is a representation of a slight different variant of the tile adaptor shown in  FIGS. 6 and 7 . In this version, tile adaptor  10 F includes means  42  to attach a shower curtain  46  via a pole  44 , or other element suitable for suspending the curtain  46 . 
         [0056]      FIG. 9  illustrates wall tile adaptor  10 E in use in combination with a floor tile adaptor  50 , the features of which are described more particularly below. Like all variants of the wall tile adaptors, floor adaptor  50  includes one or a plurality of ridges or flanges  55  which serve to align tiles both within and outside of the bathing enclosure  100 . 
         [0057]      FIG. 10  shows a slightly different alternative to the arrangement illustrated in  FIG. 9 , wherein wall tile adaptor  10 F is substituted for wall tile adaptor  10 E. Tile adaptor  10 F includes means  42  to attach a shower curtain  46  via a pole  44 , or other element suitable for suspending the curtain  46 . 
         [0058]      FIG. 11  shows a first embodiment of a floor tile adaptor  50  in accordance with the present invention. This floor adaptor  50  resembles a rectangular prism with open ends  51  and with a cutaway section  52  destined to be positioned over the drain hole  27  of the bathing apparatus. The cutaway section  52  includes a water receptacle  64  that includes a drain  60 . A water inlet  62  ensures that water from the bathing apparatus is channeled to the water receptacle  64  and thence to the drain  60 . 
         [0059]    As further shown in  FIG. 11 , the floor tile adaptor  50  is further characterized by having one or a plurality of ridges or flanges  55  which serve to align tiles. A distinction may be made between inward ridges or flanges  55 , which align tiles within a bathing apparatus, and outward ridges or flanges  55 ′, shown in  FIG. 12 , which align tiles outside the bathing apparatus. The floor tile adaptor  50  may additional include end flanges  56  at its extremities  51  to assist in the position of wall tile within the bathing apparatus. The tile adaptor  50 , which is fixed to the ground of the bathing apparatus, includes a detachable cover  58 . As illustrated in this figure, the detachable cover  58  overlaps the entire length of the floor tile adaptor  50 , but it may be shortened or otherwise configured to protect only the cutaway section  52 . 
         [0060]      FIG. 12  represents an alternative embodiment of the floor tile adaptor  50  shown in  FIG. 11 . In this embodiment  50 A, there is no cutaway section, instead, water receptacle  64  takes up nearly the entire length of the floor tile adaptor  50 . The floor tile adaptor further includes inner walls  68 ,  68 ′ which abut the water receptacle  64  either in a symmetrical or asymmetrical fashion, as shown here. The drain hole  61  is clearly visible in this drawing, as are the inward flanges  55 , the outward flanges  55 ′ and the end flanges  56 . 
         [0061]      FIG. 13  is a more complete representation of the embodiment of the tile floor adaptor  50 A shown in  FIG. 12 . The purpose of the invention is apparent from this drawing: tiles  2  and  2 ′ may be aligned both inside and outside, respectively, of the bathing apparatus, as well as on adjacent walls by relying on the use of inward and outward flanges  55  and  55 ′ and end flanges  56  and  56 ′. The tiles are positioned on construction elements  70  and  72  for a limitless design opportunities. As shown here, construction element  72  is a wedge with slope that is directed downwards in the direction of the drain. A grate element  65  completes the floor tile adaptor. While it is shown only partially in  FIG. 13 , in actual use it covers the entire length of the water receptacle, thereby providing an even surface upon which the bather may stand. 
         [0062]      FIG. 14  is a cutaway view of the floor tile adaptor  50 A shown in  FIG. 13  taken along lines L-L′. The floor  150  upon which the bathing apparatus is installed is visible from this view, as are construction elements  70  and  72 , the opening for drainage fittings  62 , a portion of grate element  65 , the inner walls  68 ,  68 ′ and portions of inside and outside tiles  2  and  2 ′, respectively. 
         [0063]      FIG. 15  and  FIG. 16  are right and left hand perspective views showing the floor tile adaptor  50  in  FIG. 11  in use. The adaptor may be used to install wall tile as well as floor tile in a bathing apparatus. 
         [0064]      FIG. 17  and  FIG. 18  illustrate how the various embodiments of the floor and wall tile adaptors may be combined to create custom bathing apparatus. The variants of the floor and wall tile adaptors have been designed to fit together in order to maximize the possibilities here. In  FIG. 17 , floor tile adaptor  50 A (shown in  FIG. 13 ) is used in conjunction with wall tile adaptor  10 E (shown in  FIG. 6 ). Similarly, in  FIG. 18 , floor tile adaptor  50 A is used in conjunction with wall tile adaptor  10 D (shown in  FIG. 5 ). 
         [0065]      FIG. 19  and  FIG. 20  are perspective and enlarged views, respectively, of a second alternative embodiment of floor tile adaptor  50  shown in  FIG. 11 ,  50 B. This version of the floor tile adaptor is similar to floor tile adaptor  50  but includes a threshold element  59 . A grate element  65 A (not shown) may be positioned over the tile adaptor to complete it. 
         [0066]      FIG. 21  is a perspective view of a third alternative embodiment variation of floor tile adaptor  50  shown in  FIG. 11 ,  50 C, designed for a corner type shower apparatus. This floor tile adaptor resembles floor tile adaptor  50 B by having a threshold element  59 A. A grate element  65 B, shown only partially in  FIG. 21 , completes the tile adaptor. 
         [0067]      FIG. 22  illustrates a variant of the floor tile adaptor  50  shown in  FIG. 11 . Here, a tray element  80  with boundary  86  is attached directly to floor tile adaptor  50  in order to complete a portion or the entire floor of the bathing apparatus. This provides an alternative to the installation of tiles wherein some of the tiles of the bathing apparatus are installed within the confines of the tray, as will be described further below.  FIG. 23  is a cutaway assembled of the floor adaptor shown in  FIG. 22  taken along lines P-P′. 
         [0068]      FIGS. 24 ,  25  and  26  show how the tray element  80  is used to install tiles on the floor and wall of a bathing apparatus. Rather than applying tiles directly on the floor  150  of the bathing apparatus, the tiles are positioned on floor  85  of the tray element  80  using epoxy or urethane glue  90  or any other suitable compound for this purpose.  FIGS. 24 and 25  are, respectively, left and right hand perspective views of this, while  FIG. 26  affords a close up view of this set-up. 
         [0069]    In an alternative to the embodiment shown in  FIGS. 24 ,  25  and  26 , tray elements  80  and  86  form a watertight unit that is used to install tiles on the floor and wall of a bathing apparatus. Rather than applying tiles directly on the floor  150  of the bathing apparatus, the tiles are positioned on floor  85  of the tray element  80  using epoxy or urethane glue  90  or any other suitable compound for this purpose. The cover  58  can be solid or include openings. Since the water to be drained enters via opening  62  on the floor pan side, it may be possible to block this drainage hole with a towel. If the cover  58  includes openings, the water can rise to eventually reach the top of the threshold. The holes at the top of the cover would then reroute the drainage water in the drain, preventing a flooding in the bathroom.  FIGS. 24 and 25  are, respectively, left and right hand perspective views of this, while  FIG. 26  affords a close up view of this set-up. 
         [0070]    In another embodiment  FIGS. 24 ,  25  and  26  show the tray elements built with materials that do not need necessarily to be covered with tile for final finish. 
         [0071]      FIGS. 27 ,  28  and  29  show how floor and wall tile adaptors in accordance with the present invention may be further combined with a ceiling tile adaptor. As illustrated in these figures, a ceiling adaptor  110  comprising one or more shower heads  124  is installed over a wall tile adaptor  10 C (shown in  FIG. 4 ). Wall tile adaptor  10 C, in turn, is positioned over floor tile adaptor  50 B (shown in  FIG. 19 ). The floor and wall elements are as previously described. In the vicinity of the ceiling adaptor, vertical and horizontal construction elements  136  and  138  lend support to this section of the bathing enclosure  100 . 
         [0072]    Ceiling adaptor  110  may include a variety of features to enhance the bathing experience, including a lighting fixture  126  or a musical portal (not shown). A shower door  200  may be further attached to ceiling adaptor  110  and the floor adaptor selected in order to complete the enclosure of the bathing apparatus. This shower door may be made from glass, polymer plastic or any other suitable material, as known in the art of shower and bathtub construction. 
         [0073]    The various embodiments of the tile adaptor described above may be manufactured from a variety of different materials including, without limitation, extruded plastic, polyvinyl chloride, acrylonitrile-butadiene-styrene tripolymer, acrylic, polyurethane, fiberglass with gel coat, cast polymer, stainless steel, painted steel and aluminum, once again in keeping with teachings in the art. 
         [0074]    While the present adaptor has been described in relation to its specific use to complete a bathing apparatus, it will be appreciated that with simple variations, the adaptor may be used in other applications requiring the positioning of tiles. For example, an adaptor featuring flanges along the lines of the adaptor of the present invention may be used to create a backsplash on a kitchen wall. 
         [0075]    The above-described embodiments of the invention are intended to be examples only. Variations, alterations and modifications can be made to the particular embodiments described herein by those of skill in the art without departing from the scope of the invention, as defined in the appended claims.