CROSS-REFERENCES TO RELATED APPLICATIONSNot Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot Applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENTNot Applicable
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIXNot Applicable.
BACKGROUND OF THE INVENTION1. Field of the Invention
This invention relates generally to devices and methods for constructing finished walls around bathtubs, showers, and the like, and, more particularly, to devices and methods for facilitating the installation of finished walls by conveniently covering the water-retaining flanges found around most modern bathtubs, one-piece shower units, shower basins, and other built-in units and appliances.
2. Description of Related Art
The installation of bathtubs and showers presents particular construction challenges. Not only should the installed tub or shower be cosmetically appealing, but also it must be joined carefully with surrounding walls to prevent the seepage of water into or behind the walls.
FIG. 1 shows a typical installation of a bathing unit, such as abathtub110. Thebathtub110 is framed by wall studs, such as 2×4's112, on three sides, where finished walls will eventually be constructed. Thetub110 itself includes awater retaining flange110a,which extends around the tub on the same three sides. Thetub110 also includes atub deck110b,which usually extends around the entire tub, and atub basin110c,where water is held while bathing. During installation, thetub110 is placed on the floor, generally in a bed of mortar, and is leveled. The tub may be attached to the 2×4's112 through theflanges110ausing screws or nails. Then the finished walls may be applied.
Various practices have been developed for constructing finished walls around atub110 in an attractive and water tight manner.FIG. 2 shows a wall constructed according to a common technique. The perspective ofFIG. 2 is along line1-1 ofFIG. 1. Here, it is seem that thetub110 is placed against awall stud112, with thetub flange110ain contact with (and perhaps nailed or screwed to) thestud112. Theflange110ahas a thickness, which varies for different models of tubs, but which is generally in the range between 0.6 cm (0.25 inch) and 1 cm (0.375 inch). A spacer, such as aplywood furring strip210, is applied to thestud112 just above theflange110a.Thefurring strip210 is selected to have a thickness that matches the thickness of theflange110a.Together, theflange110aand thefurring strip210 form a planar surface upon which other layers of walling material may be applied. Generally, a section ofwall board212, such as tile backer board, is installed onto this surface and screwed or nailed through thefurring strip210 to thestud112. Thewall board212 extends approximately down to thetub deck110b.A finished wall surface, such asceramic tile216, is then applied over thewall board212. It may be applied using adhesive, with spaces between the tiles filled withgrout214. Where thetile216 meets thetub deck110b,a flexible adhesive, such assilicone glue218, may be applied to provide a further barrier against water seepage under thetiles216.
If performed properly, the construction technique shown inFIG. 2 provides a lasting, water-tight installation. We have recognized, however, that this technique is expensive, both in terms of labor and materials. In particular, the need to applyfurring strips210 adds time and expense to the installation. The thickness of theflange110ais generally measured. Then, a furring strip is selected to match its thickness. Furring strips are applied to eachstud112 surrounding the tub or shower. If the tub or shower is not perfectly square with respect to thestuds112, the flange might not touch the studs all the way around and it may be necessary to use different thicknesses of furring strips for different studs. A great deal of measuring, cutting, and even some trial-and-error is generally needed before a satisfactory result is obtained. In addition, the walls surrounding a tub generally extend beyond the perimeter of the tub itself, and may in fact extend over the entire length or width of the bathroom. To avoid a step in the walls around the tub, which may be considered unsightly in some installations, it is often necessary to fur out not only the studs around the tub, but also those extending along the entirety of each wall against which the tub is placed.
What is needed, therefore, is an improved way of installing showers, tubs, and the like, which avoids the need to use furring strips to account for the flange and therefore costs less in terms of labor and materials.
BRIEF SUMMARY OF THE INVENTIONIn accordance with one embodiment, an adapter is provided for installing a bathing unit having a water retaining flange extending up from a surface of the bathing unit to facilitate attachment to walls. The adapter includes a vertical front strip, a vertical back strip, a horizontal bottom strip joining the front strip and the back strip and forming a water impermeable channel for receiving an edge of one or more sheets of wall board, and a vertical front sealing strip extending down from the front strip for abutting the surface of the bathing unit.
In accordance with another embodiment, an adapter is provided for attaching a bathing unit to one or more surrounding walls. The adapter includes a water impermeable channel, having a front, a back, and a bottom, and extending along a length for engaging an edge of a section of wall board. The adapter further includes a sealing strip extending down from the front of the channel and having a distal edge for contacting a surface of the bathing unit and forming a seal therewith against water seepage.
In accordance with yet another embodiment, a wall is positioned at a side of a wall-integrable unit having a flange at said side extending up from a surface thereof. The wall includes a plurality of wall studs positioned vertically against the flange, a section of wall board secured to the plurality of wall studs and having a bottom edge, and an adapter positioned between the section of wall board and the wall-integrable unit. The adapter has a channel for engaging the bottom edge of the section of wall board and a sealing strip extending down from the channel, over the flange, and abutting the surface of the wall-integrable unit.
In accordance with still another embodiment, a method of installing a bathing unit having a water-retaining flange on at least one side thereof includes positioning the bathing unit against a plurality of wall studs with the flange of the bathing unit adjacent to the plurality of wall studs. The method further includes applying an adapter to an edge of a section of wall board, the adapter having a channel for engaging said edge and a sealing strip extending down from the channel away from the section of wall board, and securing the section of backer board to the plurality of wall studs with the adapter at the bottom and the sealing strip overhanging the flange.
In accordance with a still further embodiment, a method of constructing a wall at a side of a bathing unit having a water-retaining flange includes arranging a plurality of wall studs against the flange of the bathing unit. The method also includes providing a section of wall board, the section of wall board having a bottom edge, and applying an adapter to the bottom edge of the section of wall board, the adapter having a channel for engaging the bottom edge and a sealing strip extending down from the channel away from the section of wall board. The method further includes securing the section of wall board to the plurality of wall studs with the adapter at the bottom and the sealing strip overhanging the flange of the bathing unit.
In accordance with yet another embodiment, a wall includes a section of wall board having a bottom edge and an elongated adapter having a cross-section in the shape of an inverted, lowercase “h.” The adapter includes a channel within which the bottom edge of the section of wall board is disposed and a strip extending down from the channel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGSFIG. 1 is a front, perspective view of a typical bathtub installation;
FIG. 2 is a sectional view along line1-1 ofFIG. 1, showing an arrangement of materials used to finish a wall around the bathtub ofFIG. 1;
FIG. 3 is a perspective view of an adapter according to an illustrative embodiment of the invention;
FIG. 4 is a perspective view of a section of wall board with the adapter ofFIG. 3 applied to its bottom edge;
FIG. 5 is a perspective view of a wall around a bathtub, using the adapter shown inFIG. 3, at an intermediate stage of construction;
FIG. 6 is a sectional view along line1-1 ofFIG. 1, showing an arrangement according to an embodiment of the invention including tile for finishing a wall around the bathtub ofFIG. 1 using the adapter ofFIG. 3;
FIG. 7 is a variation ofFIG. 4 according to an embodiment of the invention, wherein a plastic wall covering is used instead of tile;
FIG. 8 is a flowchart showing a process according to an embodiment of the invention for installing a wall around a bathtub, or, alternatively, for installing a bathtub adjacent to an existing wall;
FIG. 9 is a perspective view of a shower basin at an early stage of construction of a finished wall around the shower basin using the adapter ofFIG. 3;
FIG. 10 is a perspective view of a one-piece shower unit at an early stage of construction of a finished wall above the one-piece shower unit using the adapter ofFIG. 3; and
FIG. 11 is a magnified view of the top-left ofFIG. 10 showing a shower flange and the adapter ofFIG. 3 used in constructing a wall above the one-piece shower unit.
DETAILED DESCRIPTION OF THE INVENTIONAs used throughout this document, the words “comprising,” “including,” and “having” are intended to set forth certain items, steps, elements, or aspects of something in an open-ended fashion. Unless a specific statement is made to the contrary, these words do not indicate a closed list to which additional things cannot be added. In addition, as used herein, the term “bathing unit” refers to any appliance or furniture used for bathing people or animals, including bath tubs, shower basins, one-piece shower units, and the like.
FIG. 3 shows anadapter300 according to an illustrative embodiment of the invention. Theadapter300 is an elongated piece having a cross-section generally in the shape of an inverted, lowercase “h.” It includes a verticalfront strip310, ahorizontal bottom strip312, avertical back strip314, and avertical sealing strip316. Thefront strip310,bottom strip312, and backstrip314 together form achannel318 that runs the length of theadapter300. The sealingstrip316 extends down from thechannel318 and is preferably coplanar with the front strip310. The sealing strip has adistal edge320. A dashed line indicates the boundary between thefront strip310 and thesealing strip316. Theadapter300 may be used to install a finished wall around a bathtub, one-piece shower unit, or shower basin, without the need for furring strips to adjust for the thickness of the flange.
FIG. 4 shows an early stage of construction of a finished wall around a bathtub. Theadapter300 is applied to thebottom edge410 of a section ofwall board212. The width of thechannel318 is preferably a close match to the thickness of thewall board212, so that theadapter300 is easily retained by friction and thewall board212 with theadapter300 applied can be easily moved around without theadapter300 falling off.
FIG. 5 shows an intermediate stage of construction. The segment ofwall board212, with theadapter300 applied, is positioned against thewall studs112 along one side of abathtub110. Thewall board212 is placed against thestuds112, with the sealingstrip316 of theadapter300 overhanging thetub flange110aand thedistal edge320 of theadapter300 touching thetub deck110b.Thewall board212 is fixed inplace using fasteners510, such as screws or nails, which are applied through thewall board212 and into thestuds112.
FIG. 6 shows a completed, tiled wall as a sectional view, from the same perspective asFIG. 2. A layer ofgrout214 is applied over thewall board212 and over the front of theadapter300. The grout114 is generally thick enough to completely obscure any step between the surface of thewall board212 and theadapter300. A bead of flexible adhesive, such assilicone glue218, is preferably applied to the space between thebottom tile216 and thetub deck110b.Optionally, prior to applying the grout and tiles, a bead of silicone glue may be applied directly along the line where thedistal edge320 of theadapter300 meets thetub deck110b.
FIG. 7 is similar toFIG. 6, but a plastic wall covering710 is shown, rather than tile. Theplastic covering710 is applied directly over thewall board212 and front of theadapter300 using adhesive. A bead of silicone is preferably applied along the line where theplastic wall710 meets thetub deck110b.
FIG. 8 shows a preferred process for constructing a finished wall around abathtub110. Atstep810, theadapter300 is cut to the desired length, which is generally the length of the wall to which theadapter300 is to be applied. Ends of adapter segments where one segment meets another segment at right angles may be miter cut at 45-degrees. Thewall board212 may also be cut to the desired size.
Atstep812, theadapter300 is applied to thebottom edge410 of the section of wall board212 (seeFIG. 4), so that thebottom edge410 sits within thechannel318 of theadapter300.
Atstep814, the section ofwall board212 with theadapter300 in place is positioned against thestuds112. Thewall board212 is oriented with theadapter300 down and thesealing strip316 facing toward the center of the bathtub110 (seeFIG. 5). In this position, the sealingstrip316 extends over thetub flange110aand itsdistal edge320 abuts the surface of the tub, i.e., thetub deck110b.Thewall board212 is then fixed inplace using fasteners510.
Often, because of errors in level and/or square, thedistal edge320 of the sealingstrip316 does not touch thetub deck110bover the entire length of theadapter300. For example, it may touch at one end of theadapter300 but not at the other. Atstep816, this error is easily addressed simply by pushing theadapter300 down so that it touches the tub deck310bat both ends and everywhere in between. It is recognized that this step may create a space between thebottom edge410 of thewall board212 and the bottom of thechannel318; however, there are no negative consequences to introducing this space as long as thebottom edge410 of the wall board412 remains at least partially inserted within thechannel318. Optionally, silicone or some other flexible adhesive may be applied along the line where the sealingstrip316 meets thetub deck110b.
With thewall board212 andadapter300 in place, a substantially flat surface is prepared that can serve as a base upon which additional wall coverings may be applied. Atstep818, a surface such as tile or plastic walling material is adhered over thewall board212 andadapter300. If tile is used, a skim coat ofgrout214 is applied and thetiles216 are set in place. Alternatively, a plastic material may be adhered directly to thewall board212 and over the front of theadapter300. In either case,silicone glue218 may be applied along the line where the finished wall covering meets thetub deck110b.
In the preferred embodiment, theadapter300 is an integral piece, with the different strips molded together to form a single unit. It may be provided in standard length segments, such as 91.4 cm (6-foot) segments. Theadapter300 is made of a water-impermeable material, such as nylon. Other materials may be used, e.g., polyvinyl chloride, polypropylene, and polystyrene, to name a few. The specific type of material is not critical, provided it is water-resistant. Preferably, however, the material should be capable of extrusion molding, as theadapter300 is economically manufactured using a standard extrusion process.
The dimensions of theadapter300 can be varied based on the target application. For example, the width of thechannel318 is preferably matched with the thickness ofwall board212 with which theadapter300 is intended to be used. Most wall board used in current bathtub installations is 1.3 cm (0.5 inches) thick. Therefore, the width of thechannel218 is preferably about 1.3 cm (0.5 inches), as well. Other applications require wall board that is only 0.6 cm (0.25 inch) thick. For those applications, adapters may be made with channels that are about 0.6 cm (0.25 inch) wide. Adapters of other widths can be made to accommodate other wall board thicknesses, as needed.Flanges110 are generally in the range between 1.9 cm (0.75 inches) and 3.5 cm (1.375 inches) tall. Therefore, the height of the sealingstrip316 is preferably at least 3.5 cm (1.375 inches), such as 3.8 cm (1.5 inches), to accommodate the tallest of these flanges. Alternatively, adapters of different height can be made for accommodating different flange heights. The heights of thefront strip310 andback strip314 are less critical; however, they are preferably tall enough to keep the adapter roughly parallel with thewall board212 and to provide enough surface area for theadapter300 to be frictionally retained on thewall board212. We have found a height of 1.9 cm (0.75 inches) for thefront strip310 and a height of 2.54 cm (1.0 inch) for theback strip314 to be sufficient.
The thicknesses of the various strips which make up theadapter300 are determined based on different factors. All of the strips are preferably thick enough to be relatively stiff and to endure the normal stresses of installation without noticeably deforming. Also, thefront strip310 andback strip314 should preferably be relatively thin. Thefront strip310 should preferably be thin enough to avoid creating a noticeable step in the finished wall applied upon it. Theback strip314 should be thin enough to avoid spacing thewall board212 substantially away from thestuds212. By forming theadapter300 with an extrusion process, it is a simple matter to make the different strips different thicknesses; however, we have found that making all the strips about 0.2 cm (0.0625-inches) nicely satisfies all the design criteria when theadapter300 is formed from any of the plastic materials identified above.
Thewall board212 used in connection with theadapter300 may be any suitable type. For bathtubs and other applications involving water, tile backer board is preferred and is indeed required according to many building codes. Examples of tile backer board include Durock® and Hardie Backer® cement boards.
Thewall studs112 used in connection with theadapter300 are generally wood studs, such as standard 2×4's. However, nothing prevents the studs from being constructed of other suitable materials, including steel, or of being different sizes.
Theadapter300 affords numerous benefits to builders and reduces construction time and materials. It effectively eliminates the task of furring out studs to account for the tub flange. Furring is not required, as theadapter300 andwall board212 themselves create a planar surface upon which tile or other walling material may be applied. Since thewall boards212 are fixed directly to thestuds112, without an interposed furring strip, there is no unsightly step created in the wall at the border of the tub. There is also no need to fur out the entire wall in these cases to avoid such a step. The cost of the furring strips is avoided, and so is the labor associated with measuring, cutting, and placing the furring strips. Theadapter300 is also forgiving. Errors in leveling the tub, or errors in square of the wall or wall board segments, can be easily compensated simply by pressing the adapter down so that thedistal edge320 touches thetub deck110aalong the entire length of the adapter. Theadapter300 also improves water tightness. The seal that is created between the sealingstrip316 and thetub deck110bprovides an additional barrier against the seepage of water into the walls. By itself it forms a tight seal, and that seal can be further improved by applying silicone or some other flexible adhesive. Thebottom edge410 of thewall board212 is also further protected against water, since it is surrounded on three sides by theadapter300.
Having described one embodiment, numerous alternative embodiments or variations can be made. For example, theadapter300 has been shown and described for use with bathtubs. However, it may be used to the same effect with other types of bathing units, such as shower basins and one-piece shower units.
FIG. 9 shows an example of anadapter300 used in connection with ashower basin910. Theshower basin910 is similar to thebathtub110. It has a vertical,water retaining flange910a,a surface ordeck910b,and acentral portion910c.Walls are generally constructed around three sides of theshower basin910. Each of these walls hasstuds112. Theadapters300 may be used in constructing finished walls essentially as described above, with similar techniques and advantages.
FIGS. 10 and 11 show theadapter300 being used with a one-piece shower unit1010.FIG. 11 is a magnified view of the upper-left corner ofFIG. 10. The one-piece shower unit1010 generally includes aflange1010a,asurface1010b,walls1010c,and abasin1010d.Although thesurface1010bis small compared to thetub deck110bandshower basin deck910b,it is generally large enough to form a surface against which thedistal edge320 of theadapter300 may abut to form a water-tight seal. Walling materials may be applied above the one-piece shower unit essentially as described above for tubs and shower basins.
Theadapter300 is not limited to use with bathing units. It may be used with any wall-integrable unit, e.g., appliances or furniture that has a flange around at least part of its perimeter and is designed to be integrated with one or more surrounding walls. These include not only appliances or furniture that are used with water, but also others, such as built-in desks, counters, and bookshelves.
As shown and described, theadapter300 is preferably an integral extruded piece, wherein all of its constituent strips are molded together. However, this is not required. Alternatively, the adapter may be assembled from separate pieces, which may be snapped, fastened, or adhered together.
As shown and described, tile and plastic walls may be constructed using theadapter300. However, these are merely examples. Other types of walling materials may be used.
In addition, the process shown inFIG. 8 is merely one example of how a wall may be constructed around a bathtub using theadapter300. Other techniques can be used. For instance, if a wall surrounding a tub or shower is longer than the width of available wall board so that multiple sheets of wall board are required, theadapter300 can be cut to match the length of the entire wall and separate sections of wall board can be fit side-by-side into thechannel318. The precise steps of installation are limited only by the skill and imagination of the installer. According to one variant, theadapter300 is placed loosely over the flange in its approximate final position and sections of wall board are inserted into its channel. According to another variant, one section of wall board is inserted into thechannel318 at one end of theadapter300 and then that section of wall board with the adapter in place is positioned over the flange. Additional sections of wall board can then be added alongside the first, each inserting into thechannel318, to complete the wall.
AlthoughFIG. 8 shows a process for constructing a finished wall around a bathtub, it is understood that the same process applies to constructing walls around other bathing units as well as around other appliances or furniture. In addition, it should be noted that, not only may the wall be constructed around the bathing unit, but also the bathing unit may be integrated with existing unfinished walls, as is commonly done for renovations. Essentially the same process may be performed in both cases.
Those skilled in the art will therefore understand that various changes in form and detail may be made to the embodiments disclosed herein without departing from the scope of the invention.