Use of rigid polyurethane foam to encapsulate plumbing in a therapy bath

Patent metadata

Field	Value
Publication number	US-9596961-B2
Application number	US-201113883810-A
Country	US
Kind code	B2
Filing date	Sep 2, 2011
Priority date	Nov 15, 2010
Publication date	Mar 21, 2017
Grant date	Mar 21, 2017

Abstract

A wall structure for a composite tub includes a surface side for facing an interior of the tub, a polyurethane layer backing and attaching to the surface side, plumbing backing the polyurethane layer, and an encapsulation layer encapsulating the plumbing and backing and attaching to the polyurethane layer so that damage to the plumbing is minimized.

First claim

What is claimed is:

1. A wall structure for a composite tub, said structure comprising:
at least one side wall extending upwardly from a bottom surface of the composite tub, wherein the at least one side wall comprises at least
a surface layer that faces an interior of the composite tub;
a structural layer having a first side attached to the surface layer and a second side opposite the first side, and wherein said structural layer comprises a rigid polyurethane foam;
plumbing directly attached to the structural layer; and
a third layer that encapsulates the plumbing, and wherein the plumbing and the third layer are comprised of a rigid polyurethane foam, and wherein the plumbing comprises a channel positioned between the structural layer and the third layer, and wherein the channel is comprised of a pair of legs attaching to and extending from said structural layer and a third leg attached to each leg of said pair of legs to form the channel.

2. The wall structure of claim 1 further comprising:
a plurality of openings formed in the at least one side wall, and wherein each opening extends through the surface layer and the structural layer to fluidly connect to the plumbing, and wherein the plumbing has a first side that faces the opening and a second side facing opposite the first side, and wherein an entire surface of the second side is directly engaged by the third layer.

3. The wall structure of claim 1 wherein an opening passes through the surface layer, the structural layer and the plumbing.

4. A wall structure for a composite tub, said structure comprising:
a surface layer that faces an interior of the composite tub;
a structural layer having a first side attached to the surface layer and a second side opposite the first side, and wherein said structural layer comprises a rigid polyurethane foam; and
a third layer including plumbing, wherein the third layer is attached directly to the second side of the structural layer, and wherein the third layer comprises a rigid polyurethane foam or elastomer, and wherein the plumbing and the third layer are comprised of the same material, and wherein the plumbing comprises a channel formed as part of the third layer and which is comprised of a pair of legs attaching to and extending from the third layer.

5. The wall structure of claim 4 wherein the channel further comprises a third leg attaching to each leg of the pair of legs.

6. A wall structure for a composite tub, said structure comprising:
a first layer having an external surface that faces an interior of the composite tub;
a second layer having a first side directly attached to the first layer and a second side opposite the first side, the second layer comprising a rigid polyurethane foam;
a third layer directly attached to the second side of the second layer, the third layer comprising a rigid polyurethane foam or elastomer;
plumbing attached to the third layer;
an opening extending from the external surface of the first layer to the plumbing; and
a fourth layer directly attached to the third layer and surrounding the plumbing, the fourth layer comprising a foam material.

7. The wall structure of claim 6 wherein the plumbing has a first side directly engaging the third layer and a second side that faces opposite the first side, and wherein an entire surface of the second side is directly engaged by the fourth layer.

Assignees

• Stokely Andrew Warren
• Geels Michael Glenn
• Delta Faucet Co

Inventors

• Stokely Andrew Warren
• Geels Michael Glenn

Classifications

• Y10T29/49

  Method of mechanical manufacture · CPC title

• A47K3/16

  Devices for fastening baths to floors or walls; Adjustable bath feet {; Lining panels or attachments therefor} · CPC title

• A47K3/04 Primary

  Built-in baths · CPC title

• A47K3/02

  Baths (combined with showers A47K3/20) · CPC title

• B05D3/12

  by mechanical means · CPC title