Walk-In Tub Door Assembly

Abstract

A walk-in tub includes a tub frame having a door frame provided in one or more of the walls of the tub frame. The tub further includes a door hingedly connected to the door frame and adapted for movement between an open position into the interior cavity of the tub and a closed position aligned with the door frame. A sealing face is provided on the door frame facing the interior cavity of the tub. A seal is disposed around a perimeter of the door for sealing the door against the sealing face when the door is in the closed position. A latching mechanism on the door is operable between a latching position and an unlatching position and includes a slidable latching pin that is slidable to engage a pin receiver in the latching position when the door is locked and disengage from the pin receiver in the unlatching position when the door is unlocked.

Claims

1-20. (canceled)

21. A door assembly for a walk-in tub, the door assembly comprising: a door having a first portion and a second portion defining a cavity therebetween, the door being adapted for movement between an open position opening into an interior cavity of the walk-in tub and a closed position; a hinge for hingedly connecting the door to the walk-in tub, the hinge being adapted for moving the door between the open position and the closed position; a seal disposed around a perimeter of the door for sealing the door against the walk-in tub when the door is in the closed position; and a latching mechanism comprising an upper latching assembly, a lower latching assembly, and a rod positioned between and co-acting with the upper latching assembly and the lower latching assembly, the latching mechanism disposed between the first portion and the second portion, the latching mechanism operable between a latching position and an unlatching position.

22. The door assembly of claim 21, wherein the latching mechanism includes at least one latching pin that is slidable to engage a corresponding pin receiver in the latching position and disengage from the pin receiver in the unlatching position.

23. The door assembly of claim 22, wherein the latching pin has a tapered end for partially engaging the pin receiver when the door is in a partially closed position to urge the door to the closed position by fully engaging the pin receiver.

24. The door assembly of claim 21, wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position.

25. The door assembly of claim 24, wherein the latching mechanism further comprises a biasing element to bias the handle to a position in which the latching mechanism is in the latching position.

26. The door assembly of claim 23, wherein the tapered end of the latching pin comprises an inclined plane to maintain the door in a closed position.

27. The door assembly of claim 26, wherein the inclined plane slideably engages an opening of the pin receiver to guide the latching pin into the opening of the pin receiver.

28. The door assembly of claim 21, wherein the upper latching assembly comprises a cam plate, the cam plate comprising a latching pin.

29. The door assembly of claim 28, wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position, wherein the upper latching assembly comprises a housing case comprising a upper pin guide, wherein operation of the handle is configured to rotate the cam plate such that the latching pin is inserted into the upper pin guide.

30. The door assembly of claim 21, wherein the lower latching assembly comprises a latching pin, the latching pin connected to the rod.

31. The door assembly of claim 30, wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position, wherein the lower latching assembly comprises a bottom bracket assembly secured to the door, the bottom bracket assembly comprising a lower pin guide, wherein operation of the handle is configured to move the latching pin such that the latching pin is inserted into the lower pin guide.

32. A walk-in tub comprising: a tub frame having a plurality of walls extending from a floor to define an interior cavity of the tub; a door frame extending through one or more of the walls, the door frame adapted for providing a doorway for ingress into the interior cavity of the tub and egress from the interior cavity of the tub; a sealing face provided on the door frame and facing the interior cavity of the tub; a door having a first portion and a second portion defining a cavity therebetween, the door being adapted for movement between an open position away from the door frame and into the interior cavity of the tub and a closed position toward the door frame and away from the interior cavity of the tub; a hinge for hingedly connecting the door to the doorway, the hinge being adapted for moving the door between the open position and the closed position; a seal disposed around a perimeter of the door for sealing the door against the sealing face when the door is in the closed position; and a latching mechanism comprising an upper latching assembly, a lower latching assembly, and a rod positioned between and co-acting with the upper latching assembly and the lower latching assembly, the latching mechanism disposed between the first portion and the second portion, the latching mechanism operable between a latching position and an unlatching position.

33. The walk-in tub of claim 32, wherein the latching mechanism includes at least one latching pin that is slidable to engage a corresponding pin receiver in the latching position and disengage from the pin receiver in the unlatching position.

34. The walk-in tub of claim 33, wherein the latching pin has a tapered end for partially engaging the pin receiver when the door in a partially closed position to urge the door to the closed position by fully engaging the pin receiver.

35. The walk-in tub of claim 32, wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position.

36. The walk-in tub of claim 35, wherein the latching mechanism further comprises a biasing element to bias the handle to a position in which the latching mechanism is in the latching position.

37. The walk-in tub of claim 36, wherein the tapered end of the latching pins comprises an inclined plane to maintain the door in a closed position.

38. The walk-in tub of claim 37, wherein the inclined plane slideably engages an opening of the pin receiver to guide the latching pin into the opening of the pin receiver.

39. The walk-in tub of claim 32, wherein the upper latching assembly comprises a cam plate, the cam plate comprising a latching pin.

40. The walk-in tub of claim 39, wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position, wherein the upper latching assembly comprises a housing case comprising a upper pin guide, wherein operation of the handle is configured to rotate the cam plate such that the latching pin is inserted into the upper pin guide.

41. The walk-in tub of claim 32, wherein the lower latching assembly comprises a latching pin, the latching pin connected to the rod.

42. The walk-in tub of claim 41, wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position, wherein the lower latching assembly comprises a bottom bracket assembly secured to the door, the bottom bracket assembly comprising a lower pin guide, wherein operation of the handle is configured to move the latching pin such that the latching pin is inserted into the lower pin guide.

43. A door assembly for a walk-in tub, the door assembly comprising: a door having a first portion and a second portion defining a cavity therebetween, the door being adapted for movement between an open position opening into an interior cavity of the walk-in tub and a closed position; a hinge for hingedly connecting the door to the walk-in tub, the hinge being adapted for moving the door between the open position and the closed position; a seal disposed around a perimeter of the door for sealing the door against the walk-in tub when the door is in the closed position; and a latching mechanism comprising an upper latching assembly, a lower latching assembly, and a rod positioned between and co-acting with the upper latching assembly and the lower latching assembly, the latching mechanism disposed between the first portion and the second portion, the latching mechanism operable between a latching position and an unlatching position, wherein the upper latching assembly comprises a cam plate, the cam plate comprising an upper latching pin wherein the latching mechanism further comprises a handle operative for moving the latching mechanism between the latching position and the unlatching position, wherein the upper latching assembly comprises a housing case comprising an upper pin guide, wherein operation of the handle is configured to rotate the cam plate such that the upper latching pin is inserted into the upper pin guide, wherein the lower latching assembly comprises a lower latching pin connected to the rod, wherein the lower latching assembly comprises a bottom bracket assembly secured to the door, the bottom bracket assembly comprising a lower pin guide, wherein operation of the handle is configured to move the lower latching pin such that the lower latching pin is inserted into the lower pin guide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a front perspective view of a walk-in tub with a door assembly in accordance with one embodiment of the present invention;

[0016] FIG. 2 is a front view of the walk-in tub illustrated in FIG. 1;

[0017] FIG. 3 is a top view of the walk-in tub illustrated in FIG. 1 showing the door assembly in a closed position;

[0018] FIG. 4 is top view of the walk-in tub illustrated in FIG. 1 showing the door assembly in an open position;

[0019] FIG. 5 is a front perspective view of a front panel of the walk-in tub illustrated in FIG. 1;

[0020] FIG. 6 is a rear view of the panel shown in FIG. 5;

[0021] FIG. 7 is a partially exploded perspective view of a walk-in tub door assembly for use with the walk-in tub illustrated in FIG. 1;

[0022] FIG. 8 is a detailed view of a latching mechanism for the walk-in tub door assembly shown in FIG. 7 in accordance with one embodiment of the present invention;

[0023] FIG. 9 is a perspective view of a latching mechanism for a walk-in tub door assembly shown in accordance with another embodiment;

[0024] FIG. 10 is an exploded view of the latching mechanism shown in FIG. 9;

[0025] FIG. 11 is a front view of a walk-in tub door having a latching mechanism in accordance with a second embodiment;

[0026] FIG. 12 is an exploded view of an upper latching assembly of the latching mechanism shown in FIG. 11;

[0027] FIG. 13 is an exploded view of a lower latching assembly of the latching mechanism shown in FIG. 11; and

[0028] FIG. 14A is a cross-sectional view of a seal in accordance with one embodiment for use with the walk-in tub illustrated in FIG. 1.

[0029] FIG. 14B is a cross-sectional view of a seal in accordance with another embodiment for use with the walk-in tub illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0030] For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

[0031] Referring to FIGS. 1-4, a walk-in tub 10 includes a tub frame 20 that is surrounded by a plurality of cover panels 30 for covering the tub frame 20. The tub frame 20 is generally defined by a plurality of upright walls 40 extending from a floor 50 to define an interior cavity 60. The walls 40 and the floor 50 are desirably formed to create a unitary, monolithic tub structure. A drain 70 is provided in the floor 50 for draining water from the interior cavity 60. A seat 80 is formed within the interior cavity 60 to define a sitting location within the tub 10. The tub 10 is formed from a waterproof material that is sanitary and resistant to corrosion. In one embodiment, the tub 10 is made from acrylic. In other embodiments, the tub 10 may be made from fiberglass, ceramic, metal, or other material. One of ordinary skill in the art will understand that various other materials may be used for manufacturing the tub 10.

[0032] A faucet 90 is provided for introducing water into the interior cavity 60 of the tub 10. A plurality of water flow controls 100 is also provided to allow the user to adjust the flow rate and temperature of the water. The tub 10 is also provided with a shelf 110 for retaining various bathing accessories, such as soap, shampoo, and the like. In some embodiments, walls 40 of the tub 10 may have a grab bar (not shown) for providing a convenient gripping surface during ingress into the tub 10 and egress from the tub 10.

[0033] With continuing reference to FIGS. 1-4, the tub 10 further includes a door frame 120 provided in at least one of the walls 40. In the embodiment shown in FIGS. 1-4, the door frame 120 extends through a wall 40 provided on one side of the tub 10. The door frame 120 is desirably molded into the wall 40 such that the door frame 120 is an integral part of the structure of the tub 10. The door frame 120 defines a doorway for ingress into the interior cavity 60 or egress therefrom. A sealing face 130 is defined around the perimeter of the door frame 120. The sealing face 130 is adapted for sealingly engaging a door 140 that encloses the interior cavity 60 of the tub 10. The sealing face 130 is oriented toward the interior cavity 60 of the tub 10 and provides a strike surface that prevents the door 140 from opening away from the tub 10.

[0034] Referring to FIGS. 5 and 6, a front cover panel 210 is provided on the exterior side of the tub 10 to conceal the tub frame 20. The cover panel 210 includes a recess defining a doorway 220 that corresponds to the door frame 120 on the tub 10. The cover panel 210 is desirably made from the same material as the tub 10. In one embodiment, the cover panel 210 is removably attachable to the tub 10 using a plurality of clips 230 provided on a back side of the cover panel 210 that faces the tub 10. The tub 10 may include a plurality of corresponding clip receivers (not shown) to receive the clips 230.

[0035] Referring back to FIGS. 3 and 4, the door 140 is hingedly attached to the door frame 120 such that the door 140 may be moved between a closed position (FIG. 3) and an open position (FIG. 4). In a closed position, the door 140 is pressed against the sealing face 130 of the door frame 120 to create a watertight connection and prevent water from leaking from the interior cavity 60 of the tub 10. Rotating the door 140 to the open position moves the door 140 away from the sealing face 130 and into the interior cavity 60 of the tub 10. In the open position, a user may enter the tub 10 through the door frame 120.

[0036] With reference to FIGS. 7 and 8, and with continuing reference to FIGS. 3 and 4, the door 140 is mounted to the door frame 120 with a hinge 150. One part of the hinge 150 is fixed to the door 140 and the other part is fixed to the door frame 120 to permit the door 140 to swing between the open position and the closed position. Bolts 160, or other fasteners, may be used to secure the hinge 150 to the door frame 120 and the door 140. The door 140 further includes a seal 170 disposed around a perimeter of the door 140 for sealing the door 140 against the sealing face 130 when the door 140 is in the closed position. The seal 170 is provided at the interface between the door 140 and the sealing face 130 such that the seal 170 is at least partially compressed between the door 140 and the sealing face 130 when the door 140 is in the closed position. The structure of the seal 170 will be described hereafter with reference to FIGS. 14A-14B.

[0037] With continuing reference to FIGS. 7 and 8, the door 140 includes a first portion 180 and a second portion 190 defining a door cavity 200 therebetween. In one embodiment, the first portion 180 is provided on the side of the door 140 that faces the interior cavity 60 of the tub, while the second portion 190 is provided on the side of the door 140 that faces the tub exterior. The door 140, including the first portion 180 and the second portion 190, is desirably made from the same material as the tub 10. In one embodiment, the door 140 is made from acrylic. In other embodiments, the door 140 may be manufactured from fiberglass, metal, plastic, or any other suitable material.

[0038] FIGS. 7 and 8 further illustrate a latching mechanism 240 operable between a latching position and an unlatching position. The latching mechanism 240 is operated to a latching position when the door 140 is in a closed position, thereby securing the door 140 against the sealing face 130 and preventing water from leaking from the interior cavity 60. In an unlatching position, the latching mechanism 240 unlocks the door 140 from the closed position, thereby permitting the door 140 to be moved to the open position. The latching mechanism 240 is operated by a handle 250 provided on the first portion 180 or the second portion 190. In one embodiment, the handle 250 may be provided on both the first portion 180 and the second portion 190 of the door 140.

[0039] Movement of the handle 250 causes the latching mechanism 240 to be operable between the latching position and the unlatching position. The handle 250 is rotatably connected to a plate 260 having a plurality of rods 270 pivotally connected to the plate 260. Rotation of the handle 250 causes the plate 260 to rotate such that the plurality of rods 270 is moved in a linear manner. The rods 270 are connected to the plate by fasteners 280 that allow the rods 270 to pivot about a connection point with the plate 260 without being disconnected therefrom. As shown in FIGS. 7 and 8, one of the rods 270 extends in a substantially vertical direction along a first axis while the other rod 270 extends in a substantially horizontal direction along a second axis. The rods 270 extend through the door 140 and are movable past the outside perimeter of the door 140. In one position, such as when the latching mechanism 240 is in an unlatched position, the rods 270 are withdrawn inside the door cavity 200 to permit the door 140 to open. In a second position, such as when the latching mechanism 240 is operated to a latching position, the rods 270 are moved to extend outside the door cavity 200 in order to lock the door 140 within the door frame 120.

[0040] With continuing reference to FIGS. 7 and 8, and with reference to FIGS. 9 and 10, rods 270 terminate in a latching pin 290 that is slidable in a linear manner with the movement of the rods 270. The latching pin 290 desirably has a tapered point 300 (shown in FIGS. 9 and 10). When door 140 is moved to the closed position such that the sealing face 130 abuts the perimeter of the door 140, the door 140 may be locked in the closed position by operating the handle 250 to move the latching mechanism 240 in the latching position. Such movement of the latching mechanism 240 causes the rods 270 to move in a linear manner away from the interior of the door cavity 200. Movement of the rods 270 causes the latching pin 290 to extend outside the door 140 and to engage a pin receiver 310 on the door frame 120. The pin receiver 310 may be fastened to the door frame 120, or it may be molded into the door frame 120. The pin receiver 310 includes a central opening 320 sized to receive the latching pin 290. A corresponding pin guide 330 may be provided on the door 140 to guide the latching pin 290 toward the pin receiver 310.

[0041] With reference to FIGS. 9 and 10, the tapered point 300 of the latching pin 310 provides a mechanical advantage in closing the door 140 and maintaining the door 140 in the closed position. The tapered point 300 guides the latching pin 290 into the central opening 320 of the pin receiver 310, thereby urging the door 140 to the closed position and compressing the seal 170 between the door 140 and the sealing face 130 on the door frame 120. The tapered point 300 is desirably shaped as to guide the latching pin 290 into the central opening 320 of the pin receiver 310.

[0042] With reference to FIG. 11, a latching mechanism 400 is shown in accordance with a second embodiment. The latching mechanism 400 is operable between a latching position and an unlatching position. The latching mechanism 400 is operated to a latching position when the door 140 is in a closed position, thereby locking the door 140 against the sealing face 130 and preventing water from leaking from the interior cavity. In an unlatching position, the latching mechanism 400 unlocks the door 140 from the closed position, thereby permitting the door 140 to be moved to the open position. The latching mechanism 400 is operated by a handle 410 provided on an inside portion of the door 140.

[0043] Movement of the handle 410 causes the latching mechanism 400 to be operable between the latching position and the unlatching position. The handle 410 is rotatably connected to a cam plate 420 having a rod 430 pivotally connected to the cam plate 420. Rotation of the handle 400 causes the cam plate 420 to rotate such that the rod 430 is moved in a linear manner. In one position, such as when the latching mechanism 400 is in an unlatched position, the rod 430 is withdrawn inside the door cavity 200. In a second position, such as when the latching mechanism 400 is operated to a latching position, the rod 430 is moved to extend outside the door cavity 200.

[0044] With continuing reference to FIG. 11, the latching mechanism 400 includes an upper latching assembly 440 (shown in greater detail in FIG. 12) and a lower latching assembly 450 (shown in greater detail in FIG. 13). Referring to FIG. 12, the upper latching assembly 440 includes a housing case 460 that is secured to the door 140. The housing case 460 supports a backing plate 470 and the cam plate 420 having an upper latching pin 480 secured thereon. The upper latching pin 480 extends through an upper pin guide 490 of the housing case 460. Handle 410 (shown in FIG. 111) is connected to a shaft 500 that is operatively connected to the cam plate 420 such that rotation of the shaft 500 causes a corresponding rotation of the cam plate 410. A spring 510 provides a biasing force on the cam plate 420 to return the handle 410 to its default position. The upper latching pin 480 desirably has a tapered point 580 at its terminal end. The tapered point 580 is desirably shaped as to guide the latching pin 480 into the central opening of the upper pin guide 490.

[0045] Referring to FIG. 13, the lower latching assembly 450 includes a bottom bracket assembly 520 that is secured to the inside portion of the door 140. The lower portion of the rod 430 (shown in FIG. 11) is connected to a lower latching pin 530 by a fastener 540. The lower latching pin 530 is disposed within the bottom bracket assembly 520 and is movable relative to a lower pin guide 550. The lower latching assembly 450 further includes a roll pin 560 extending through the lower latching pin 530 to engage a lower spring 570 when the lower latching pin 530 is extended to a latching position. The lower latching pin 530 desirably has a tapered point 590 at its terminal end.

[0046] When door 140 is moved to the closed position, the door 140 may be locked in the closed position by operating the handle 410 to move the latching mechanism 400 in the latching position. The tapered points 580, 590 of the upper and lower latching pins 480, 530, respectively, provide an inclined-plane mechanical advantage in closing the door 140 and maintaining the door 140 in the closed position. The tapered points 580, 590 guide the latching pins 480, 530 into a central opening of the pin receiver provided on the door, thereby drawing the door 140 closed and compressing the seal between the door 140 and the sealing face 130 on the door frame 120. The tapered points 580, 590 are desirably shaped as to guide the upper and lower latching pins 480, 530 into the opening of the pin receiver. Alternatively, or in addition, the pin receiver may have a tapered surface to guide the latching pins 480, 530.

[0047] With reference to FIG. 14A, a cross sectional view of the seal 170 is illustrated in combination with a seal retainer 340. The seal retainer 340 is secured to the outside perimeter of the door 140 or it may be integrally formed with the door 140. In one embodiment, the seal retainer is formed as a groove on the door 140 to provide a guide for the installation of the seal 170. The seal retainer 340 is desirably provided on the side of the door 140 that engages the sealing face 130, such as illustrated in FIG. 4. In order to provide a watertight connection between the door 140 and the sealing face 130 of the tub 10, the seal retainer 340 is provided along the entire interface between the door 140 and the sealing face 130. In one embodiment, the seal retainer may be provided on the sealing face 130 and the door 140 may be pressed against the sealing face 130 to compress the seal 170. The seal 170 may be secured within the seal retainer 340, such as by an adhesive bond.

[0048] With continuing reference to FIG. 14A, the seal retainer 340 receives a first portion 350 of the seal 170. The seal 170 further includes a second portion 360 that is compressible between the door 140 and the sealing face 130 of the tub 10. The second portion 360 of the seal 170 includes a plurality of hollow cavities that are compressible when the door 140 is in the closed position. In the embodiment shown in FIG. 14A, a larger central cavity 370 is flanked by two smaller lateral cavities 380 provided on the exterior of the central cavity 370. The central cavity 370 and the lateral cavities 380 are compressible between a fully extended shape when the door 140 is in the opened position and the seal 170 is decompressed and a collapsed shape when the door 140 is in the closed position and the seal 170 is compressed. In one embodiment, the seal 170 is made from an elastic material, such as rubber or silicone. Other flexible and resilient materials may be used to create the watertight connection between the door 140 and sealing face 130.

[0049] FIG. 14B illustrates another embodiment of the seal 170. The seal 170 has a base 600 having one or more barbs 610 configured for being received within a seal retainer 340. The seal 170 further includes a second portion 620 that is compressible between the door 140 and the sealing face 130 of the tub 10. The second portion 620 of the seal 170 includes a hollow cavity 630 that is compressible between the door 140 and the sealing face 130 when the door 140 is in the closed position. The hollow cavity 630 is compressible between a fully extended shape when the door 140 is in the opened position and a collapsed shape when the door 140 is in the closed position.

[0050] Having described the walk-in tub 10 and the door assembly for the walk-in tub 10, a method of operation of the door assembly will now be described. Prior to entering the interior cavity 60 of the tub 10, a user first rotates the handle 250, 410 to ensure that the latching mechanism 240, 400 is in the unlatched position such that the door 140 can be swung open into the interior cavity 60. After opening the door 140 to allow ingress, the user may step into the interior cavity 60 of the tub 10. The door 140 is then moved to the closed position by swinging the door 140 toward the sealing face 130 of the door frame 120. As the door 140 nears the sealing face 130, the seal 170 contacts the sealing face 130. Continued movement of the door 140 toward the sealing face 130 causes the seal 170 to be compressed. The user turns the handle 250 to activate the latching mechanism 240, 400 and close the door 140 to create a watertight connection between the door 140 and the sealing face 130 of the door frame 120. Engaging the latching mechanism 240, 400 into the latching position causes the rods 270, 430 to extend away from the door cavity. Linear movement of the rods 270, 430 causes the latching pins 290, 480, 530 to engage the central opening of the pin receiver such that the door 140 is further drawn toward the sealing face 130. This causes the seal 170 to be compressed even further, thereby establishing a watertight connection that prevents leakage of water from the interior cavity 60 outside the tub 10.

[0051] While various embodiments of the walk-in tub door assembly were provided in the foregoing description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. For example, it is to be understood that this disclosure contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims and all changes to the invention that fall within the meaning and the range of equivalency of the claims are to be embraced within their scope.