Abstract: The present invention provides a method for manufacturing a door for a walk-in bathtub, which comprises forming a tub door cap from an acrylic sheet, wherein the tub door cap has an outer shape defining a door for a walk-in tub; forming a channel into a surface of the tub door cap along a peripheral area thereof; forming a threshold portion configured to mate with the channel in the tub door cap and extend outwardly from the tub door cap; and the tub door cap is then adhered to the threshold portion of the door to form a walk-in tub door. The acrylic sheet that forms the tub door cap may be cast acrylic or it may be reinforced by co-extruding with thermoplastic, adding a reinforcing filler and/or fiberglass. A walk-in bathtub door made by the method described above and a walk-in bathtub assembly having a door made by the method described above are also provided herein.

Abstract: The disclosure concerns a door assembly for a walk-in bathtub that includes a door that fits within a door threshold in the wall of the walk-in tub. The door assembly further comprises a hinge assembly that includes a first axis mount coupled to the door threshold and a second axis mount coupled to the outer side of the door. A double axis hinge is coupled to both axis mounts, to thereby connect the door to the bathtub. The double axis hinge is able to open the door towards the inside of the tub by pivoting about the first axis toward the inside of the bathtub as the door in turn counter rotates about the second axis at the distal end of the hinge, in the direction opposite to that of the hinge.

Abstract: The present invention provides a drain system for a walk-in bathtub. The drain system includes a conventional drain opening in the bottom of the walk-in bathtub and a second drain opening in the side of the foot well of the bathtub. A motorized pump pumps water out of the bathtub through the second drain opening in the foot well. A first drain line provides water outflow from the conventional drain opening to a primary drain pipe. A second drain line provides outflow from the motorized pump to the primary drain pipe, and a third drain line joins the primary drain pipe from an overflow opening near the top of the bathtub. A low water sensor is coupled to the second drain line and motorized pump and deactivates the pump when the water level in the bathtub is equal to or lower than the second drain opening.

Abstract: The present invention provides a method for manufacturing a door for a walk-in bathtub, which comprises forming a tub door cap from an acrylic sheet, wherein the tub door cap has an outer shape defining a door for a walk-in tub; forming a channel into a surface of the tub door cap along a peripheral area thereof; forming a threshold portion configured to mate with the channel in the tub door cap and extend outwardly from the tub door cap; and the tub door cap is then adhered to the threshold portion of the door to form a walk-in tub door. The acrylic sheet that forms the tub door cap may be cast acrylic or it may be reinforced by co-extruding with thermoplastic, adding a reinforcing filler and/or fiberglass. A walk-in bathtub door made by the method described above and a walk-in bathtub assembly having a door made by the method described above are also provided herein.

Abstract: The present invention provides a door assembly for a walk-in bathtub. The invention includes a door that fits within a door threshold in a wall of the walk-in tub. The door assembly further comprises a hinge assembly that includes a first axis mount coupled to the door threshold and a second axis mount coupled to the outer side of the door. A double axis hinge is coupled to both axis mounts, thereby connecting the door to the bathtub. The double axis hinge opens the door to the inside of the tub by pivoting about the first axis toward the interior of the bathtub as the door in turn counter rotates about the second axis at the distal end of the hinge, in the direction opposite to that of the hinge.

Abstract: The present invention provides a method for manufacturing a walk-in bathtub. The method involves heating an acrylic sheet, wherein the outer perimeter of the sheet is heated to a higher temperature than the center of the sheet. The heated acrylic sheet is then placed over a vacuum mold that is shaped like a bathtub, including a seat and a foot well, and drawn into the mold by the vacuum. Vacuum pressure is manually reduced when the acrylic reaches the top of the seat in the mold, and the vacuum is shut off when the acrylic is approximately two inches from the bottom of the foot well of the mold. The acrylic is removed from the mold, reinforced with fiberglass and secured to a support frame. A door space is cut in the side of the tub and a pre-hung door assembly is then installed in the door threshold.

Abstract: The present invention provides a drain system for a walk-in bathtub. The drain system includes a conventional drain opening in the bottom of the walk-in bathtub and a second drain opening in the side of the foot well of the bathtub. A motorized pump pumps water out of the bathtub through the second drain opening in the foot well. A first drain line provides water outflow from the conventional drain opening to a primary drain pipe. A second drain line provides outflow from the motorized pump to the primary drain pipe, and a third drain line joins the primary drain pipe from an overflow opening near the top of the bathtub. A low water sensor is coupled to the second drain line and motorized pump and deactivates the pump when the water level in the bathtub is equal to or lower than the second drain opening.

Abstract: The present invention provides a door assembly for a walk-in bathtub. The assembly includes a frame shaped to fit a door threshold in the side of the walk-in bathtub, wherein the frame includes a track dedicated to accommodating a gasket along the length of the frame. The frame also includes a track dedicated to accommodating door hinges. In the preferred embodiment of the invention, the frame is made of a single extruded piece of aluminum that is powder coated to match the acrylic surface of the walk-in tub. The door is mounted onto the frame with hinges. A gasket is inserted into the track in the door frame and forms a water tight seal between the door and the frame. The door assembly can be installed in the bathtub as a separate, pre-assembled system, similar to a pre-hung door.

Abstract: The present invention provides a method for manufacturing a walk-in bathtub. The method involves heating an acrylic sheet, wherein the outer perimeter of the sheet is heated to a higher temperature than the center of the sheet. The heated acrylic sheet is then placed over a vacuum mold that is shaped like a bathtub, including a seat and a foot well, and drawn into the mold by the vacuum. Vacuum pressure is manually reduced when the acrylic reaches the top of the seat in the mold, and the vacuum is shut off when the acrylic is approximately two inches from the bottom of the foot well of the mold. The acrylic is removed from the mold, reinforced with fiberglass and secured to a support frame. A door space is cut in the side of the tub and a pre-hung door assembly is then installed in the door threshold.

Abstract: The present invention provides a door assembly for a walk-in bathtub. The assembly includes a frame shaped to fit a door threshold in the side of the walk-in bathtub, wherein the frame includes a track dedicated to accommodating a gasket along the length of the frame. The frame also includes a track dedicated to accommodating door hinges. In the preferred embodiment of the invention, the frame is made of a single extruded piece of aluminum that is powder coated to match the acrylic surface of the walk-in tub. The door is mounted onto the frame with hinges. A gasket is inserted into the track in the door frame and forms a water tight seal between the door and the frame. The door assembly can be installed in the bathtub as a separate, pre-assembled system, similar to a pre-hung door.