US20080000022A1

US20080000022A1 - Protective liner

Info

Publication number: US20080000022A1
Application number: US11/428,044
Authority: US
Inventors: Ray Sieben
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-06-30
Filing date: 2006-06-30
Publication date: 2008-01-03

Abstract

The invention is directed to a device and method of protecting a bathtub or shower unit during the construction of a building. The device is a pre-molded polymer foam liner that is placed inside the bathtub or shower unit and that is then removed upon the completion of the construction. The liner can be easily adapted to match holes in the bathtub or shower unit as the case may be.

Description

FIELD OF THE INVENTION

The present invention relates to a device and a method of protecting bathtubs and shower units, and in particular to protecting bathtubs and shower units during the construction of a building.

BACKGROUND

During the framing stage of construction of a building it is common practice to place bathtubs and shower units (collectively referred to as “bathing fixtures”) in the rooms that that they will eventually be installed in. Consequently, such bathing fixtures are exposed to a substantial portion of the construction and finishing process. During construction, bathing fixtures are inadvertently subjected to a variety of physical abuses including rain, dirty footwear, rocks, nails, staples, screws, ladders, stilts, trowels, knives, dropped tiles and general use as a garbage receptacle. Such physical abuse frequently damages the exposed surfaces of the bathing fixtures manifesting itself in the form of stains, scratches, dents and chips.
Various types of cover have been used to try and protect bathing fixtures during the construction process. Many of the covers that have been tried are makeshift in nature having little effect, or even compounding the damage. Wooden and cardboard covers have been used but they tend to slide around on the surface of the bathing fixtures causing scratches at the point of contact. Further, trades people frequently discard such covers because the cover physically interferes with their tasks such as tiling, framing and plumbing. Paper based covers are also of limited utility as they tend to disintegrate if subjected to moisture.
Covers have been tried that incorporate attachment devices such as magnets and suction cups however, they have had limited success and are unduly complex to produce and use. Another suggested solution is the use of rigid vinyl or hard plastic liners. Such liners are expensive and complicated to make and they are bulky to transport to the work site. Another problem is that such hard liners obstruct the subsequent plumbing of the faucets and plug assembly. As a result they are often removed and discarded by trade people. A further problem with rigid liners is their inability to absorb the impact of heavy objects dropped on to the bathing fixture resulting in damage to the underlying section of the bathing fixture.
Therefore, what is required is an inexpensive protective cover that does not unduly interfere with the ability of the trades people to complete their tasks, that is tightly fitted to the bathing fixture to stay in place and to prevent the entry of foreign objects under underneath the cover, and which is strong enough to protect the underlying surface from unwanted physical contact. It would also be preferable if the protective cover were water resistant and reusable.

SUMMARY OF THE INVENTION

The present invention is directed to a device and method for protecting bathing fixtures during the construction of a building.
Accordingly, in one aspect of the invention, the invention comprises a liner that is inserted into a bathtub, having an interior surface and a deck, to protect the bathtub during the construction of a building, the liner comprising a unitary pre-molded flexible polymer foam liner formed to match the contours of the interior surface and the deck.
In one aspect of the present invention, the invention comprises a liner that is inserted into a shower unit to protect the shower unit during the construction of a building, the shower unit having an interior surface and an upper rim, the liner comprising a unitary pre-molded flexible polymer foam liner formed to match the contours of the interior surface and the upper rim.
In one aspect of the present invention the invention comprises a unitary pre-molded foam liner for a bathing fixture that is pre-molded by spraying liquid foam onto a bathing fixture mold.
In one embodiment, the liner has pre-formed holes to correspond with openings in the bathing fixture. In one embodiment the polymer is polyurethane. In another embodiment the polymer is rubber, and in a further embodiment, the polymer is silicone.
In a further aspect of the invention, the invention comprises a method of protecting a bathtub having a deck and an interior surface during the construction of a building comprising the steps of:

- (a) pre-molding a unitary polymer foam liner by spraying a polymer foam in liquid form onto a mold of the bathtub and removing it once the polymer foam solidifies;
- (b) inserting the polymer foam liner in the bathtub so the deck and the interior surface are completely covered;
- (c) cutting holes in the polymer foam liner to correspond with holes in the interior surface and deck; and
- (d) removing the polymer foam liner and any debris contained therein upon completion of the construction.

In a further aspect of the invention, the invention comprises a method of protecting a shower unit having an interior surface and an upper rim during the construction of a building comprising the steps of:

- (a) pre-molding a unitary polymer foam liner by spraying a polymer foam in liquid form onto a mold of the shower unit and removing it once the foam solidifies;
- (b) inserting the polymer foam liner in the shower unit so the upper rim and the interior surface are completely covered;
- (c) cutting holes in the foam liner to correspond with holes in the interior surface; and
- (d) removing the polymer foam liner and any debris contained therein upon completion of the construction.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of an exemplary embodiment with reference to the accompanying simplified, diagrammatic, not-to-scale drawings. In the drawings:

FIG. 1 is a diagrammatic depiction of a conventional bathtub.

FIG. 2 is a cross sectional view of a conventional bathtub.

FIG. 3 is a diagrammatic depiction of a conventional shower unit.

FIG. 4 is a cross sectional view of a conventional shower unit.

FIG. 5 is a cross sectional view of a conventional bathtub with one embodiment of the present invention inserted into it.

FIG. 6 is a cross sectional view of a conventional shower unit with one embodiment of the present invention inserted into it.

DETAILED DESCRIPTION OF THE INVENTION

Scope

The present invention provides for a method and device for protecting bathing fixtures during the construction of a building. When describing the present invention, all terms not defined herein have their common art-recognized meanings. To the extent that the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the claimed invention. The following description is intended to cover all alternatives, modifications and equivalents that are included in the spirit and scope of the invention, as defined in the appended claims.

Definitions

In this patent the following words are intended to have the following meaning:

- 1. “Bathing fixtures” shall collectively refer to bathtubs and shower units.
- 2. “Foam” shall mean a substance that is formed by trapping many gas bubbles in a liquid or solid.
- 3. “Polymer” shall mean a naturally occurring or synthetic compound consisting of large molecules comprising of a linked series of repeated monomers. Suitable polymers described herein include polyurethane, rubber and silicone.

All terms not defined herein have their common art-recognized meanings.

Description

The present invention is directed to a device and method of protecting bathing fixtures during the construction of a building. FIGS. 1 and 2 show a conventional bathtub (12) having a deck (14) and an interior surface (20) comprising a floor (18) and a dam (16). The floor (18) has a drain hole opening (24) and FIGS. 1 and 2 show faucet holes in the deck (14) and the dam (16) respectively. There is also commonly an overflow opening (26) as seen in FIG. 2. FIGS. 3 and 4 depict a conventional shower unit (30) having an upper rim (32) and an interior surface (38), the interior surface comprising a floor (36) and at least one wall (34). The floor (36) has an opening for a drain hole (24) and a wall may have an opening, or openings (22) for a faucet as shown in FIGS. 3 and 4. It should be understood that the present invention may be used with shower units and bathtubs made from any material including with out limitation metal, vinyl and fiberglass. It should be further understood that the present invention may be used with shower units and bathtubs of any design and shape including those having additional features such as seats and integral soap ledges.
The protective device is a unitary pre-molded polymer foam liner (40) that is flexible yet strong enough resist tearing and puncture through the regular wear that bathing fixtures are subjected to during the construction process. The polymer foam is preferably thick enough and dense enough to cushion the blow of impact of any undesired physical contact from such things as dropped tiles or tools. The polymer is also preferably water resistant. Any suitable polymer may be used. Preferred polymers include polyurethane, rubber and silicone. It has been found by the inventor that if polyurethane foam is used, a layer of foam from one quarter to half an inch thick will provide adequate cushioning however, the thickness of the foam may be increased if greater protection is desired. It has also been determined that polyurethane foam having a six pounds per cubic foot density rating is a suitable type for use however, the density of the foam can be increased if greater protection is desired.
The liner (40) is inexpensive and simple to produce. The polymer foam in liquid form is sprayed in a relatively uniform layer onto a mold of the bathing fixture that is to be protected. The mold may be specifically constructed, or alternatively, it may simply comprise a bathtub or shower unit of the corresponding model to be protected that has been modified to be suitable for use as a mold. The mold may be coated with releasing agent prior to the application of the polymer foam. All surfaces of the bathtub requiring protection are covered with the liquid polymer foam on the corresponding mold. The polymer foam is applied to the desired depth. The polymer foam is allowed to dry and solidify and is then peeled as a single piece from the mold. The resulting light-weight pre-molded polymer foam liner may be rolled or folded to facilitate transportation and shipping to the user, and ultimately to the worksite.
As shown in FIGS. 5 and 6, the liner is inserted into the bathtub (12) or shower unit (30) so that all surfaces that require protection are covered. In the bathtub (12) the liner (40) covers the interior surface (20) and the deck (14). In the shower unit (30) the liner (40) covers the interior surface (38) and the upper rim (32). As shown in the figures, the liner may be extended beyond the deck (14) and the upper rim (32) to prevent slippage of the liner (40) within the bathing fixture. As can be seen in FIGS. 5 and 6, by virtue of its shape, the pre-molded liner (40) is in close physical contact with the entire interior surface of the bathing fixture thereby preventing the entry of any debris or waste between the liner and the interior surface of the bathing fixture. The pre-molded liner (40) will remain in place even when subjected to external forces such as feet and does not require any additional attachment means. The liner (40) is water resistant and can be reused multiple times. At the completion of the construction process, the liner (40) may be removed form the bathing fixture in the same manner that a garbage bag is removed from a garbage can, thereby removing all accumulated debris and waste at once.
The present invention is very easy to modify to create holes that match the holes in the bathing fixture for such things as drain holes, faucets and jets. Holes may be pre-formed in the liner (40) during the molding process. However, although standard designs are used for bathing fixtures, the placement and configuration of the holes in the fixture varies greatly. The liner (40) of the present invention may be inserted in the bathing fixture without any holes and then when its is time to plumb the fixture in, holes may be cut in the liner very easily using a craft knife or other suitable cutting implement. Alternatively, if the model of bathing fixture has openings that are consistently placed such as the drain hole or the overflow opening, then corresponding openings may be formed in the liner (40) at the manufacturing stage. This beneficial aspect of the liner (40) means that trades people will not be impeded in their activities involving the openings in the bathing fixture and thus, the liner will be more likely not to be removed and discarded. This is a significant improvement on rigid liners that are difficult and cumbersome to try modify in such a manner. The present liner (40) may be modified quickly and efficiently to accommodate the myriad of opening configurations.
The use of the liner (40) will now be described in relation to the protection of a bathtub, however it will be understood that the method described would have equal application to a shower unit. The first step is to obtain a mold of the bathtub that requires protection. Releasing agent is applied to the mold and then liquid polymer foam is applied in a uniform layer to the deck (14) and interior surface (20) to the desired depth. Any suitable method of application of the polymer foam may be used including spraying. If desired, holes may be preformed in the liner at this stage to correspond with standard openings in the bathing fixture such as drain holes and overflow openings. The polymer foam is allowed to dry and the liner is then peeled from the mold. Curing agents as would be used by one skilled in the art may be used to promote the solidification of the liquid polymer foam. The pre-molded liner (40) is then transported to the worksite and is placed in the bathtub (12) and aligned so that it covers the entire interior surface (20) and the deck (14). A knife can then be used to cut holes in the liner (40) to create holes that are aligned with, and correspond to, the holes in the bathtub (12) such as the faucet holes (22). Upon completion of the construction, the top section of the liner (40) located on the deck (14) is gathered and the liner (40) is lifted out of the bathtub with all of the debris and garbage contained within the liner (40). The polymer foam is strong enough to support the weight of the debris without ripping. The garbage and debris is discarded and the liner may be cleaned and used for another job.
As will be apparent to those skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the scope of the invention claimed herein.

Claims

1. A liner that is inserted into a bathtub to protect the bathtub during the construction of a building, the bathtub having an interior surface and a deck, the interior surface having a drain hole opening and an overflow opening, the liner comprising a unitary pre-molded flexible polymer foam liner formed to match the contours of the interior surface and the deck of the bathtub.

2. The liner of claim 1 further comprising pre-formed holes that correspond with the overflow opening and the drain hole opening.

3. The liner of claim 1 wherein the polymer is a polyurethane.

4. The liner of claim 1 wherein the polymer is rubber.

5. The liner of claim 1 wherein the polymer is silicone.

6. A liner that is inserted into a bathtub to protect the bathtub during the construction of a building, the bathtub having an interior surface and a deck, the liner comprising a unitary pre-molded flexible polymer foam liner formed to match the contours of the interior surface and the deck, whereby the polymer foam liner is manufactured by spraying the polymer foam in liquid form onto a bathtub mold and removing it from the mold once the polymer foam has solidified.

7. A liner that is inserted into a shower unit to protect the shower unit during the construction of a building, the shower unit having an interior surface and an upper rim, the interior surface having a drain hole opening, the liner comprising a unitary pre-molded flexible polymer foam liner formed to match the contours of the interior surface and the upper rim.

8. The liner of claim 7 further comprising a preformed hole to correspond with the drain hole opening.

9. The liner of claim 7 wherein the polymer is polyurethane.

10. The liner of claim 7 wherein the polymer is rubber.

11. The liner of claim 7 wherein the polymer is silicone.

12. A liner that is inserted into a shower unit to protect the shower unit during the construction of a building, the shower unit having an interior surface and an upper rim, the liner comprising a unitary pre-molded flexible polymer foam liner formed to match the contours of the interior surface and the upper rim, whereby the polymer foam liner is manufactured by spraying the polymer foam in liquid form onto a shower unit mold and removing it from the mold once the polymer foam has solidified

13. A method of protecting a bathtub having a deck and an interior surface during the construction of a building comprising the steps of:

(a) pre-molding a unitary polymer foam liner by spraying a polymer foam in liquid form onto a mold of the bathtub and removing it once the polymer foam solidifies;

(b) inserting the polymer foam liner in the bathtub so the deck and the interior surface are completely covered;

(c) cutting holes in the polymer foam liner to correspond with any openings in the interior surface and deck; and

(d) removing the polymer foam liner and any debris contained therein upon completion of the construction.

14. The method of claim 13 wherein the polymer is polyurethane.

15. The method of claim 13 wherein the polymer is rubber.

16. The method of claim 13 wherein the polymer is silicone.

17. A method of protecting a shower unit having an interior surface and an upper rim during the construction of a building comprising the steps of:

(a) pre-molding a unitary polymer foam liner by spraying a polymer foam in liquid form onto a mold of the shower unit and removing it once the polymer foam solidifies;

(b) inserting the polymer foam liner in the shower unit so the upper rim and the interior surface are completely covered;

(c) cutting holes in the foam liner to correspond with holes in the interior surface; and

18. The method of claim 17 wherein the polymer is polyurethane.

19. The method of claim 17 wherein the polymer is rubber.

20. The method of claim 17 wherein the polymer is silicone.