Bathing Assembly with Water Collection and Dispersion

This non-provisional patent application is filed by applicants American Bath Group, LLC a Delaware company and Maax Bath Inc. of Montreal, Canada, for the inventors Marc-Yvan Meilert, a citizen of Canada, residing in Quebec, Christine Lacasse-Veilleux, a citizen of Canada, residing in Quebec, and Steve Donnelly a citizen of Canada, residing in Quebec, for the invention of an “Improved Bathing Assembly with Water Collection and Dispersion”.

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

All patents and publications described or discussed herein are hereby incorporated by reference in their entirety.

The present disclosure relates to bathing assemblies, which can also be described as shower surrounds, shower units, or showers, bathtubs with surrounds, bath units. More particularly, the present disclosure relates to bathing assemblies that reduce installation time, improve fluid collection and dispersion, and direct fluids from the bathinging process to a collection area.

Bathing assemblies, bathing units, bathtub assemblies, or showers, are known in the art. Bathing assemblies are typically combinations of manufactured and assembled walls, and potentially a base, or shower pan, that are either freestanding or attached to walls of a building or dwelling, such as a home, office, hospital, or the like, to provide a location, such as in a bathroom, for someone to clean themselves. Bathing units are usually manufactured at a facility, or factory, and then shipped to the location where the bathing unit will be installed.

Bathing assemblies generally come and two forms. The first is a fully complete unit that is formed or manufactured as a whole piece in the factory. The second is a bathing unit that is made in pieces and ship to the building in pieces and assembled on site. Many aspects factor into which of the two bathing units are made. These including the style of the unit, the size of the unit, the space within the building where the unit will be placed, construction of the building where the unit will be placed, and egress to the location where the bathing unit will be installed. In situations where a unit is shipped in pieces and then assembled, the construction of that unit within the bathroom where it is installed can be time and labor-intensive. Traditionally during the installation process, a sealant, such as caulk, is used in the assembly of the bathing unit. The sealant is normally hand laid by the construction worker and is used to try and to restrict water flow from exiting the bathing area at the seams and joints defined between the various pieces of the bathing unit.

Traditionally, water issues can arise if the installation person does not properly seal the bathing unit. For example, if the unit is not properly assembled, which traditional means a liberal use of sealant, water can escape through gaps, cracks, and crevices between the pieces and get behind the bathing unit. This moisture behind the walls can make the walls and surrounding areas behind the bathing unit damp. If unchecked, this dampness can lead to mold growth and in some cases deterioration, damage, and destruction to the structure of the building around the bathing unit, including the walls, such as sheet rock or dry walls, the insulation, and supports, such as the wooden studs and flooring of the building used as support for the bathing unit itself.

The problem of maintaining the water within the confines and structure of the bathing unit can be further exacerbated by modern bathing unit design that can include multiple water dispersion locations, such as multiple shower heads, and high-pressure dispersion locations. The use of these multiple and/or high-pressure water dispersion locations can increase the likelihood that water will penetrate even small seams, joints, or gaps left by the installation process, or naturally occurring in the bathing unit once assembled. These multiple locations and high-pressure dispersions can also send water high in the air. This can lead to water hitting surfaces above the tops of the bathing unit walls. Again, this can lead to water getting behind the bathing unit walls and cause the afore mentioned mold and damage issues.

Additional problems associated with conventional bathing units and the modern showering processes are the additional fluids used in the cleaning process. Most people that take showers use various cleaning products during the showering process, such as some form of soap, shampoo, and even conditioner. Most of these products have a “suds” effect that is designed to aid in the cleaning process. These remnants of the cleaning products travel with the water in the shower and are spread about the shower area, especially with the deflection of the fluids by the water off of the body of the person showering or bathing. This can lead to a buildup of these remnants throughout the bathing area. These remnants can also be pushed by the water into the seams, joints, or gaps left from the assembly process as previously mentioned. These fluids can further exacerbate the mold and damage issues with additional fluids behind the walls of the bathing units.

What is needed then are improved bathing units that can be assembled quickly and efficiently. These improved bathing units preferably have integrated fluid collection features and systems that direct fluids away from the walls of the structure to which they are installed and to the drain of the bathing unit.

The present disclosure provides bathing units for placement proximate to one or more walls of a building. The bathing units have improved assembly characteristics and integrated water collection and dispersion features.

In a particular embodiment, an exemplary of a bathing unit for placement proximate to one or more walls of a building as disclosed herein may include a base, a first panel, a second panel, and an extruded channel. The base may include a length, a width, a collection area, a first edge, and a second edge. The first panel may include a wall side, an exposed side, a first height, a first panel attaching side, and a first base end. The first base end may be shaped to engage at least the first edge of the base. The first panel attaching side may include a first flange extending from the wall side away from the exposed side. The second panel may include a wall side, an exposed side, a second height approximately equal the first height, a second panel attaching side, and a second base end. The second base end may be shaped to engage the second edge of the base. The second panel attaching side may include a second flange extending from the wall side away from the exposed side. The second panel attaching side may be configured to be positioned adjacent to the first panel attaching side. The extruded channel may be configured to receive the first flange and the second flange. The extruded channel may be shaped to direct water from the first and second flanges down toward the base and away from the one or more walls.

In an exemplary aspect according to the above-referenced embodiment, the extruded channel may be configured to be coupled to one of the one or more walls of the building independent of the first and second panels.

In another exemplary aspect according to the above-referenced embodiment, the base may include a recessed channel aligned with the extruded channel. The recessed channel may be shaped to receive water from the extruded channel and direct the water toward the collection area.

In another exemplary aspect according to the above-referenced embodiment, the recessed channel may include an engagement protrusion configured to engage a lower end of the extruded channel.

In another exemplary aspect according to the above-referenced embodiment, the first and second panel attaching sides may be aligned with the recessed channel.

In another exemplary aspect according to the above-referenced embodiment, the first edge may include a first back splash extending therefrom such that a lower portion of the extruded channel overlaps the first back splash.

In another exemplary aspect according to the above-referenced embodiment, the first base end of the first panel may be shaped to further engage a portion of the second edge of the base.

In another exemplary aspect according to the above-referenced embodiment, the first flange may include a first portion extending perpendicularly from the wall side at the first panel attaching side and a second portion angled relative to the first portion. The second flange may include a first portion extending perpendicularly from the wall side at the second panel attaching side and a second portion angled relative to the first portion. The second portion of the second flange may be configured to be adjacent to the second portion of the first flange when the first and second panels are positioned adjacent to each other and resting on the base.

In another exemplary aspect according to the above-referenced embodiment, the base may include a third edge. The bathing unit may further include a third panel including a wall side, an exposed side, a third height approximately equal to the first height, a third panel attaching side, and a third base end. The third base end may be shaped to engage at least the third edge of the base. The third panel attaching side may include a third flange extending from the wall side away from the exposed side. The second panel may include a mirror panel attaching side. The mirror panel attaching side may include a mirror flange extending from the wall side away from the exposed side. The mirror panel attaching side may be configured to be positioned adjacent to the third panel attaching side. The bathing unit may further include an additional extruded channel configured to receive the third flange and the mirror flange. The additional extruded channel may be shaped to direct water from the third flange and the mirror flange down toward the base and away from the one or more walls.

In another exemplary aspect according to the above-referenced embodiment, the second panel may include a lower portion and an upper portion.

In another embodiment, bathing unit for placement proximate to one or more walls of a building as disclosed herein may include a base, a first panel, and a second panel. The base may include a length, a width, a collection area, a first edge, a second edge, and at least one recessed channel defined in at least one of the first edge or the second edge to direct water towards the collection area. The first panel may include a wall side, an exposed side, a first height, a first panel attaching side, and a first base end. The first base end may be shaped to engage the first edge of the base. The second panel may include a wall side, an exposed side, a second height approximately equal the first height, a second panel attaching side, and a second base end. The second base end may be shaped to engage the second edge. The second panel attaching side may be configured to be positioned adjacent to the first panel attaching side. A first recessed channel of the at least one recessed channel may align with the first and second panel attaching sides when positioned adjacent to each other and resting on the base. The first recessed channel may be shaped to receive water from the first and second panel attaching sides and direct the water toward the collection area.

In an exemplary aspect according to the above-referenced embodiment, the bathing unit may further include a u-shaped extrusion aligned with the first recessed channel. The u-shaped extrusion may be configured to receive a first flange of the first panel attaching side and a second flange of the second panel attaching side. The u-shaped extrusion shaped to direct water from the first and second flanges down toward the base and away from the one or more walls

In another exemplary aspect according to the above-referenced embodiment, the recessed channel may include a boss configured to engage a lower end of the u-shaped extrusion.

In another exemplary aspect according to the above-referenced embodiment, the first edge may include a first back splash extending therefrom. A lower portion of the u-shaped extrusion may be configured to overlaps the first back splash

In another exemplary aspect according to the above-referenced embodiment, the u-shaped extrusion may extend a majority of the first height and is independent of the first and second panels.

In another embodiment, method of installing a bathing unit proximate to one or more walls of a building as disclosed herein may include positioning a base proximate to the one or more walls of the building, the base having a collection area, a first edge, a second edge, and a first recessed channel defined in the second edge to direct water towards the collection area; aligning a first u-shaped extrusion with the first recessed channel, the first u-shaped extrusion configured to extend vertically from the base; engaging at least the first edge of the base with a first panel, the first panel configured to extend vertically from the base and including a first flange configured to be received by the first u-shaped extrusion; and engaging the second edge of the base with a second panel, the second panel configured to extend vertically from the base and including a second flange configured to be received by the first u-shaped extrusion.

In an exemplary aspect according to the above-referenced embodiment, the step of aligning the first u-shaped extrusion may include coupling the first u-shaped extrusion to one of the one or more walls of the building.

In another exemplary aspect according to the above-referenced embodiment, the step of aligning the first u-shaped extrusion may include overlapping the first u-shaped extrusion with a back splash of the base.

In another exemplary aspect according to the above-referenced embodiment, the method may further include receiving a lower end of the first u-shaped extrusion by a boss of the first recessed channel.

In another exemplary aspect according to the above-referenced embodiment, the method may further include aligning a second u-shaped extrusion with a second recessed channel of the base, the second recessed channel defined in the second edge; and engaging at least a third edge of the base with a third panel, the third panel configured to extend vertically from the base and including a third flange configured to be received by the second u-shaped extrusion, wherein the second panel includes a mirror panel attaching side, the mirror panel attaching side including a mirror flange configured to be received by the second u-shaped extrusion.

It is therefore a general object of the current disclosure to provide a bathing unit with an improved fluid collection and dispersion system.

Another object of the current disclosure is to provide a bathing unit designed to keep fluid from getting behind the walls of the unit.

Still another object of the current disclosure is to provide a bathing unit that does not need a sealant during assembly.

Still another object of the current disclosure is to provide a bathing unit that has multiple locations to direct fluid back to the base collection area of the bathing unit.

Numerous other objects, features and advantages of the present disclosure will be readily apparent to those skilled in the art upon a reading of the following description when taken in conjunction with the accompanying drawings.

Reference will now be made in detail to embodiments of the present disclosure, one or more drawings of which are set forth herein. Each drawing is provided by way of explanation of the present disclosure and is not a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the teachings of the present disclosure without departing from the scope of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment.

Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present disclosure are disclosed in, or are obvious from, the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

The words “connected”, “attached”, “joined”, “mounted”, “fastened”, and the like should be interpreted to mean any manner of joining two objects including, but not limited to, the use of any fasteners such as screws, nuts and bolts, bolts, pin and clevis, and the like allowing for a stationary, translatable, or pivotable relationship; using any resin, glue, epoxy, and the like; being integrally formed as a single part together; any mechanical fit such as a friction fit, interference fit, slidable fit, rotatable fit, pivotable fit, and the like; any combination thereof; and the like.

Unless specifically stated otherwise, any part of the apparatus of the present disclosure may be made of any appropriate or suitable material including, but not limited to, metal, alloy, polymer, polymer mixture, wood, composite, or any combination thereof.

Referring generally now to, one embodiment of the present disclosure provides a bathing unit. It is understood that, for the sake of clarity, not all reference numbers are included in each drawing. In addition, positional terms such as a “upper,” “lower,” “side,” “top,” “bottom,” “vertical,” “horizontal,” etc. refer to the apparatus when in the orientation shown in the drawing. The skilled artisan will recognize that objects in accordance with the present disclosure can assume different orientations when in use.

Referring now to, the bathing unit, which can also be described as a shower assembly, shower surround, shower, bath assembly, bath surround, or bath, is preferably manufactured, assembled and attached to walls (shown in) of a building (not shown). The building can be any of those buildings known in the art, such as a dwelling, home, office, hospital, and the like, that has a location, such as in a bathroom, for someone to clean himself or herself. Typically, the walls to which the bathing unitis attached will include a surface, such as sheet rock or dry wall, insulation, and supports, such as the wooden studs. The bathing unit will also typically be supported by flooring of the building, such as additional supports and subflooring, as is known in the art.

In a preferred embodiment, the bathing unitmay include a base, a first panel, a second panel, a third panel, a first u-shaped extrusion, and a second u-shaped extrusion. The baseincludes a collection area, a first edge, and a second edge, the first and second edges can be described as flanges, such as, for example, horizontal flanges elevated from the collection area. The length and width of the basecan vary according designer preference and to conform to the space where the bathing unitis to be installed. The collection areacan include a drainas known in the art. The collection areais designed to collect the fluids from the showering or bathing process and direct them to the drain and ultimate removal from the bathing area. The basecan include a trough areato direct water collected during the showing process towards the collection areaand to the drain. The first and second u-shaped extrusions,may also be referred to herein as first and second extruded channels,and may vary in shape while maintaining a general channel shape. The first and second u-shaped extrusions,may be coupled to one of the one or more walls of the building independent of the baseand the first, second, and third panels,,.

The first panelmay include a wall sideand an exposed side, or exposed surface, while the second panelmay include a wall sideand an exposed side, or exposed surface. The wall sidesandare designed to set against and attach to walls of the dwelling where the bathing unitis positioned. The exposed sidesandare designed to direct water down to the collection areaof the baseand can have any aesthetically pleasing appearance as desired and known in the art.

The first panelmay include a first base endshaped to engage at least the first edgeof the base, while the second panelincludes a second base endshaped to engage the second edgeof the base. In some embodiments, a portion of the first base endmay be shaped in engage a portion of the second edgeof the base. This engagement positions the exposed sides,within the footprint of the baseto facilitate fluid movement down the to the collection areaduring the showering or bathing process.

The first panelmay include a first panel attaching sidewith a first flangeextending from the wall sideaway from the exposed side. The second panelmay include a second panel attaching sidewith a second flangeextending from the wall sideaway from the exposed side. As best seen in, the first panel attaching sidemay be configured to be positioned adjacent to the second panel attaching sidesuch that the first flangeand the second flangeare at least partially engaged with at least a portion received by the first u-shaped extrusion. The first u-shaped extrusionmay be configured to receive water from the first and second flanges,and direct the water down towards the baseaway from the one or more walls of the building. In the examples shown in the figures, the first flangemay include a first portionextending perpendicularly from the wall sideat the first panel attaching sideand a second portionangled relative to the first portion. The second flangemay include a first portionextending perpendicularly from the wall sideat the second panel attaching sideand a second portionangled relative to the first portion. The second portionof the second flangemay be configured to be adjacent to the second portionof the first flangewhen the first and second panels,are positioned adjacent to each other and resting on the base. For example, the second portions,of the first and second flanges,may be angled in a same direction to mate together when received by the first u-shaped extrusion. In certain optional embodiments, the first and second portions,,,of the first and second flanges,may be shaped differently and/or include different features such as channels or the like.

The third panelcan be a mirror of the first panel. As such, the third panelmay include a wall side, an exposed side, or exposed surface, a third heightapproximately equal to the first height, a third panel attaching sideand a third base endshaped to engage at least the third edgeof the base. The third panelcan connect to a mirror panel attaching sideof the second panelwhen it is desired to have three walls as part of the bathing unit. This can be accomplished by the third panelhaving a third flange, similar to the first flange, and the second panelhaving a mirror flange, similar to the second flange, each of which may be received by the second u-shaped extrusion. The second u-shaped extrusionmay be configured to receive water from the mirror and third flanges,and direct the water down towards the baseaway from the one or more walls of the building.

The first flangemay be offset from one or more of the first base endor an upper end of the first panel. Likewise, the second flangemay be offset from one or more of the second base endor an upper end of the second panel. Further, the third flangeand the mirror flangemay be offset from third base endor an upper end of the third paneland the second base endor the upper end of the second panel, respectively. The offset of the flanges may help properly align the panels vertically with each other when installed to the base.

As illustrated in, the basemay include at least one recessed channelconfigured to allow water to flow from underneath the first, second, or third panels,,and into the collection areaof the base. A first recessed channelmay be aligned with the first u-shaped extrusionand a second recessed channelmay be aligned with the second u-shaped extrusion. As such, the first panel attaching sideof the first paneland the second panel attaching sideof the second panelmay be aligned with the first recessed channelwhen positioned adjacent to each other and resting on the base.

As further illustrated in, the basemay further include a water dampositioned at an end of each of the first and second edges,of the baseopposite the second edge. As such, as illustrated in, the first panelmay include an indentationconfigured to mate with the water damof the first edgeof the basewhen the first panelis mated with the base. Likewise, the third panelmay also include an indentation (not numbered) mirroring the indentationof the first panel. As illustrated in, the water damis configured to prevent water traveling under the first or third panels,and beyond the front edge of the base.