SHOWER TRIM KIT

Abstract

A shower trim component for installation with a shower fixture, the shower trim component including an escutcheon formed of a material selected from the group consisting of glass, gravel, marble, paper, stone, wood and wood products. The escutcheon may include an electronic component embedded in the escutcheon.

Description

RELATED APPLICATIONS

This patent application is a divisional application of U.S. patent application Ser. No. 11/072,399, filed 7 Mar. 2005, currently pending.

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to the field of plumbing. Specifically, the present invention is of an improved shower trim kit that is not only easy to install but also allows for greater freedom in providing a shower with a desired appearance than heretofore known. The present invention is also of a method for installing a shower trim kit and methods for making the shower trim kit.

In the art it is known to install the lion's share of the components of a shower fixture within a wall 10 in proximity of a shower head 12, FIG. 1. Generally the water supply connections and valves are substantially found within wall 10 while only the necessary functional components such as shower heads (e.g., 12), spouts (e.g. 14), hose fed hand showers (not depicted) and control handles (valve handle 18, diverter knob 20) are found on the outside of wall 10.

Many different types of shower fixtures exist having different types and numbers of control handles.

For example, different shower fixtures have a different number (e.g., 1, 2, 3 or more) and arrangement of outlet ports. Diversion of water to one or more of the outlet ports is performed using a diverter knob. In FIG. 1, diverter knob 20 allows diversion of water to one of two different outlet ports, associated with shower head 12 or spout 14.

For example, different fixtures have a different number (e.g., 1, 2, 3 or more) and arrangement of valve handles. Many shower fixtures include two stem valves, a first stem valve for regulating hot water flow and a second stem valve for regulating cold water flow to a mixer. Rotation of one or the other valve handle protruding from the wall and functionally associated with a respective stem valve stem allows selection of a desired water temperature and water flow rate. Many such showers fixtures include a third stem valve located at the output port of the mixer. Rotation of the valve handle protruding from the wall and functionally associated with the third stem valve allows selection of the water flow rate. Valve handles that are fit over a stem of a stem valve are known to be made of many different types of material including glass, ceramic, metals, plastics or combinations thereof. As a stem valve is made of a plumbing-compatible metal such as brass, a valve handle is generally provided with a brass adapter to engage features on the stem (e.g., serrations, flat sides, discontinuities) to allow effective rotation of the stem. As the only motion required from such a valve handle is rotation, attachment of a brass adapter to a valve handle of a given material is not technically challenging. An additional advantage of such a construction is that valve handles of various styles, shapes, materials and forms can be fitted onto standard stems and changed when desired. This allows an interior designer, esthetic freedom when designing a shower. Further, replacement of an undesired valve handle is simple and cheap to perform even by an unskilled person.

A preferred shower fixture, such as depicted in FIG. 1, includes a pressure balancing valve. In a pressure balancing valve a single valve handle 18 controls the showering conditions. Pulling or pushing handle 18 determines the water flow rate while rotation of handle 18 determines the water temperature. Pressure balancing valves are preferred over other types of valves as the necessity for only one valve handle renders such fixtures exceptionally esthetic and easily useable. A disadvantage of pressure balancing valves is that the valve handle must be longer than required in stem valves so that the structural stress on such a handle is much higher than in a stem valve handle. Further, stress-inducing forces applied during use are not exclusively rotational as in stem valves. As a result, pressure balancing valve handles are, unitary structures made of a single piece of material. Such a structure does not give an interior designer much freedom in selecting a desired esthetic form. Further, once a handle is installed a skilled plumber is required to replace the handle.

As a shower walls such as 10 are generally covered with water-resistant tiles, the locations from whence the exterior parts of a shower fixture protrude include gaps formed by breaking or cutting the tiles. Not only are the edges of the gaps unesthetic, but the view through the gaps to the inside of wall 10 gives the whole an unhygienic, unfinished and unsophisticated “construction site” look. If the gap is not sealed, water condensing on the tiles flows down and through the gap into the interior of wall 10, defeating the purpose of the tiling and generating conditions conducive for the formation of mold and mildew in wall 10.

To overcome the problems caused by the presence of gaps in a shower wall 10, shower trim kits are used. Shower trim kits generally include a number of different components such as flanges (e.g. 26 and 28), valve trim (e.g., 30) and escutcheons (e.g., 32).

As is known to one skilled in the art, shower trim kits are not only decorative features but are functional, providing protection for the inner part of a wall and the shower fixture itself. Further, factors such as the aesthetic appearance and ease of installation of a given shower trim kit are determinants of the value of the shower trim kit.

Although effective in preventing water from passing into a wall 10 and effective in concealing gaps so that a shower is given an aesthetic finished look, prior art shower trim kits fail in a number of aspects as the various components are made of stamped metals made of or treated so as to look like chrome, brass, nickel, copper or stainless steel. Although generally attractive, cheap and simple to manufacture, stamped metal has only limited aesthetic and design possibilities. Thus a manufacturer of shower trim kits is able to offer only a limited selection of flanges and escutcheons to an interior designer from which to choose. Thus, even though valve handles for stem valves are available in many different esthetic forms and made of many different materials, an interior designer is limited to stamped metal flanges and escutcheons.

It would be advantageous to have a shower trim kit devoid of at least some of the disadvantages of the prior art. It would be most advantageous that a shower trim kit be available in many materials and shapes.

SUMMARY OF THE INVENTION

The present invention successfully addresses at least some of the shortcomings of the prior art by providing an improved shower trim kit, an improved method for installing an escutcheon or pressure balancing valve handle and an improved method for producing an escutcheon.

According to the teachings of the present invention there is provided a shower trim kit for installation with a shower fixture comprising a substantially non-metal escutcheon, preferably a molded or carved escutcheon. Embodiments of an escutcheon of the present invention comprise materials such as acrylic, cement, ceramics, clay, elastomers, enamels, epoxies, foams, glasses, glass-ceramics, gravel, gypsum, marble, mortar, paper, recycled paper, plaster, plastics, polyacrylates, polycarbonates, polyester, polymers, polystyrene, polyurethane, polyvinyl chloride, rubber, silicon rubber, silicon oxide, sponge, stone, styrofoam, terra cotta, rubber, wood, plywood and wood products, although epoxies/polyesters and combinations thereof are preferred. Also preferred are wood, clay and clay-like materials.

In embodiments of the present invention, the escutcheon comprises at least two layers of material, for example an inner polyester layer covered with an outer epoxy layer, preferably a transparent epoxy layer.

In embodiments of the present invention the escutcheon is coated with a coating. A specific coating is selected to be suitable for coating the material from which the escutcheon is made and includes, but is not limited to, enamel, epoxy, glass, lacquer, paints, plastic, polymer, shellac and stains. Preferably the coating is water-resistant.

In embodiments of the present invention the escutcheon comprises a material (including when the material makes up part of the coating) having a property selected from the group consisting of fluorescence, phosphorescence and/or reflectivity.

In an embodiment of the present invention at least part of the escutcheon is transparent. In a preferred embodiment the escutcheon comprises at least two layers, wherein an upper of the at least two layers is transparent. In an embodiment of the present invention, there is a solid object suspended inside a transparent part of the escutcheon. Any suitable solid object is appropriate, including but not limited to animal products, coral, feathers, insects, leather, shells, skeletons, spines, teeth, plant products, bark, fruit, leaves, pits, roots, twigs, sawdust, seeds, cloth, fabric, flakes, grains, gravel, metal, paper, particles, pebbles, sand, stones, strips and wires.

In an embodiment of the present invention, the shower trim kit further comprises a switch embedded within the escutcheon. In an embodiment of the present invention, the shower trim kit further comprises a temperature sensor functionally associated with the switch wherein the switch is configured to toggle between an activated and deactivated state dependent on output from the temperature sensor, e.g., when the temperature in the shower cabin is above a certain predetermined level. In an embodiment of the present invention, the shower trim kit further comprises a component functionally associated with the switch.

Suitable components include light-emitting components (lamps, light emitting diodes), motion-producing components (electrical motors) and sound-producing components (music synthesizers, music players).

In a preferred embodiment, the shower trim kit includes, in addition to an escutcheon, at least one outer valve handle configured to fit over a valve handle of a shower fixture. Preferably the at least one outer valve handle matches the escutcheon, for example having the same color, a contrasting color or being made of substantially the same material as the escutcheon.

According to the teachings of the present invention there is also provided a shower trim kit comprising an outer valve handle configured to fit over the valve handle of a pressure balancing valve. Embodiments of an outer valve handle of the present invention comprise materials such as acrylic, cement, ceramics, clay, elastomers, enamels, epoxies, glasses, glass-ceramics, gravel, gypsum marble, metals, mortar, paper, recycled paper, plaster, plastics, polyacrylates, polycarbonates, polyesters, polymers, polystyrenes, polyurethanes, polyvinyl chlorides, rubber, silicon rubber, silicon oxide, stone, terra cotta, rubber, wood, plywood and wood products, although epoxies/polyesters and combinations thereof are preferred. Also preferred are wood, clay and clay-like materials.

In embodiments of the present invention, the outer valve handles comprises at least two layers of material, for example an inner polyester layer covered with an outer epoxy layer, preferably a transparent epoxy layer.

In embodiments of the present invention the outer valve handle is coated with a coating. A specific coating is selected to be suitable for coating the material from which the outer valve handle is made and includes, but is not limited to, enamel, epoxy, glass, lacquer, paint, physical vapor deposit, plastic, polymer, powder coating, shellac and stains. Preferred is that the coating be water-resistant.

In embodiments of the present invention the outer valve handle comprises a material (including when the material makes up part of the coating) having a property selected from the group consisting of fluorescence, phosphorescence and/or reflectivity.

In an embodiment of the present invention, at least part of the outer valve handle is transparent. In a preferred embodiment the outer valve handle comprises at least two layers, wherein an upper of the at least two layers is transparent. In an embodiment of the present invention, there is a solid object suspended inside a transparent part of the outer valve handle. Any suitable solid object is appropriate, including but not limited to animal products, coral, feathers, insects, leather, shells, skeletons, spines, teeth, plant products, bark, fruit, leaves, pits, roots, twigs, sawdust, seeds, cloth, fabric, flakes, grains, gravel, metal, paper, particles, pebbles, sand, stones, strips and wires.

In an embodiment of the present invention, the outer valve handle includes a hollowed-out interior volume configured to receive the valve handle of the pressure balancing valve. In an embodiment of the present invention, the shower fixture kit further comprises at least one compressible fixing component (preferably ring-shaped, like an 0-ring) configured to apply a force on the valve handle and on a surface of the hollowed-out interior volume of the outer valve handle so as to fix the outer valve handle in place over the valve handle. In an embodiment of the present invention, an outer surface of the valve handle is provided with an annular slot configured to receive the ring-shaped compressible fixing component. In an embodiment of the present invention, the surface of the hollowed-out interior volume of the outer valve handle is provided with an annular slot configured to receive the ring-shaped compressible fixing component.

In a preferred embodiment, the shower trim kit includes an escutcheon in addition to an outer valve handle. Preferably the escutcheon matches the outer valve handle, for example having the same color, a contrasting color or being made of substantially the same material as the outer valve handle.

According to the teachings of the present invention there is also provided a method of installing an escutcheon of the present invention over a shower fixture located inside a wall by providing a non-metal escutcheon having at least one hole therethrough and affixing the escutcheon in place so that a component (for example, one or more valves, a diverter knob, a hand shower) of the shower fixture is accessible through the at least one hole. In an embodiment, the escutcheon is affixed to the wall by a method including using a material such as adhesive, adhesive tape (especially double-sided adhesive tape), caulk, polymerizable material, sealant or silicon rubber so as to stick the escutcheon to the wall. In an embodiment of the present invention, the escutcheon is affixed to the wall by placing the escutcheon so that a part of the shower fixture protrudes through the hole (for example, a flange or seat of a valve such as pressure balancing valve flange) and snugly placing an elastic holding member (e.g., a ring-shaped object such as an O-ring) about the protruding part of the shower fixture so as to press the escutcheon in place against the wall.

According to the teachings of the present invention there is also provided a method of installing an outer valve handle over a valve handle of a pressure balancing valve located inside a wall, comprising: providing an outer valve handle configured to fit over the valve handle and placing the outer valve handle over the valve handle, preferably by pushing the outer valve handle over the valve handle.

According to the teachings of the present invention there is also provided a method of producing an escutcheon having a hole therethrough comprising providing a moldable precursor material (for example, a polymerizable material, a powders, a fluid, a liquid, a foam or a thermoplastic material), placing the moldable precursor material in an escutcheon-shaped mold, fixing the moldable precursor material so as to fashion an incipient escutcheon and processing the incipient escutcheon so as to fashion the escutcheon. In an embodiment of the present, invention the escutcheon-shaped mold includes a feature corresponding to the hole. In an embodiment of the present invention the hole is made in the incipient escutcheon during the processing, for example, by boring, drilling or trephining.

In an embodiment of the present invention fixing the the moldable precursor material comprises a method selected from the group consisting of heating the precursor material, cooling the precursor material, polymerizing the precursor material, cross-linking the precursor material, curing the precursor material, irradiating the precursor material, illuminating the precursor material, exposing the precursor material to a fixative and waiting a period of time.

In a preferred embodiment, the moldable precursor material includes a thermoplastic material at plastic temperature and the fixing comprises cooling the thermoplastic material, for example as part of a thermoforming process.

In a preferred embodiment, the moldable precursor material includes a polymerizable material and the fixing comprises polymerizing the polymerizable material. Suitable polymerizable materials include but are not limited to monomer solutions, crosslinkable polymers, vulcanizable polymers, polymerizable fluids and thermosetting resins.

In embodiments of the present invention by processing is meant simply transferring the fixed escutcheon from one place to the other. In embodiments of the present invention processing the incipient escutcheon includes using methods such as abrading, brushing, coating, coloring, lacquering, painting, polishing, sand blasting, sanding, shellacing, spraying, staining and varnishing the incipient escutcheon.

In an embodiment of the present invention, prior to fixing the moldable precursor material, an additional material is added to the moldable precursor material. Suitable additional materials include but are not limited to animal products, coral, feathers, insects, leather, shells, skeletons, spines, teeth, plant products, bark, fruit, leaves, pits, roots, twigs, sawdust, seeds, cloth, fabric, flakes, grains, gravel, metal, paper, particles, pebbles, sand, stones, strips and wires.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.

In the drawings:

FIG. 1 (prior art) depicts a shower cabin having a shower fixture including a pressure balancing valve with a prior art valve handle and a prior art escutcheon;

FIG. 2A depicts a shower cabin having a shower fixture including a pressure balancing valve with a valve handle of the present invention and an escutcheon of the present invention;

FIGS. 2B and 2C are enlarged cross-sectional views of a valve handle and escutcheons of the present invention;

FIG. 3 is a side view of a shower fixture including an escutcheon of the present invention with a light emitting object suspended therein; and

FIGS. 4 and 5 depict escutcheons of the present invention.

DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION

The present invention is of a shower trim kit including a non-metal escutcheon, a method of making the non-metal escutcheon and a method of installing an escutcheon. The present invention is also of a shower trim kit including an improved pressure balancing valve handle and a method of installing such a valve handle.

The principles and uses of the teachings of the present invention may be better understood with reference to the accompanying description and figures. In the figures, like reference numerals refer to like parts throughout.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details set forth herein.

The invention can be implemented with other embodiments and can be practiced or carried out in various ways. It is also understood that the phraseology and terminology employed herein is for descriptive purpose and should not be regarded as limiting.

Generally, the nomenclature used herein and the procedures utilized in the present invention include techniques from the fields of plumbing, material science and engineering.

Such techniques are thoroughly explained in the literature. Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. In addition, the descriptions, materials, methods, and examples are illustrative only and not intended to be limiting. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention.

As used herein, the terms “comprising” and “including” or grammatical variants thereof are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof. This term encompasses the terms “consisting of” and “consisting essentially of”.

The phrase “consisting essentially of” or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed device or method.

The term “method” refers to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the engineering and construction arts. Implementation of the methods of the present invention involves performing or completing selected tasks or steps manually, automatically, or a combination thereof.

Shower Trim Kit of the Present Invention

A first aspect of the present invention is a shower trim kit comprising a substantially non-metal escutcheon 32 as depicted in FIG. 2A. Preferably such a shower trim kit also includes one or more valve handles, especially valve handles that match escutcheon 32, for example by color, material, texture or theme. The advantages of the first aspect of the present invention is that escutcheons are provided that are not only superior in allowing one skilled in the art of interior design heretofore unknown freedom in providing a desired appearance to a shower, but also ease installation and replacement, when compared to prior art escutcheons.

A second aspect of the present invention is a shower trim kit comprising an outer valve handle 34 configured to fit over a valve handle 36 of a pressure balancing valve, as depicted in FIGS. 2A, 2B and 2C. Preferably such a shower trim kit also includes a escutcheon, especially an escutcheon that matches valve handle 36, for example by color, material, texture or theme. The advantages of the second aspect of the present invention is that outer valve handles are provided that are not only superior in allowing one skilled in the art of interior design heretofore unknown freedom in providing a desired appearance to a shower, but also ease installation and replacement of a outer shower valve handle as desired. This is exceptionally significant during construction of buildings such as hotels and apartment blocks. A skilled plumber installs a shower fixture including a pressure balancing valve with a valve handle 36 in every shower cabin in the building. Subsequently, an interior designer can easily customize the appearance of each shower cabin as desired without requiring the assistance of a plumber by installing an outer valve handle of the present invention, such as 34. The second aspect of the present invention is discussed in detail hereinbelow.

Preferably, the first and second aspects of the present invention are combined in one unified shower trim kit, as depicted in FIG. 2A. In such a way, a standard shower fixture including a pressure balancing valve is provided, and is customizable in situ as desired using a shower trim kit of the present invention including both the first and second aspect of the present invention. This allows simplified mass-production and installation of a single yet easily customizable shower fixture.

The present invention allows heretofore unknown esthetic possibilities.

Using known shower trim kits, an interior designer is limited to using stamped metal escutcheons having colors used in the field of metal coating. In contrast, by employing the teachings of the present invention, a designer is not limited in the choice of colors. In some embodiments, an outer valve handle of the present invention is installed in a shower. In some embodiments, a escutcheon of the present invention is installed in a shower. In a preferred embodiment, an escutcheon of the present invention and outer valve handle(s) are installed in a shower, especially when the valve handle(s) and the escutcheon match (for example, by color, material, pattern or theme). For example, in a shower tiled with ceramic tiles having a brown marble appearance installation of a cream colored escutcheon together with brown marble appearance outer valve handle(s) both made of an acrylic polymer giving an exceptionally attractive appearance. If a designer is no longer satisfied with the appearance of either or both the escutcheon and the outer valve handles(s), either or both are replaced without the assistance of a skilled plumber. Further, custom outer valve handles may be easily produced and installed.

Using known shower trim kits, an interior designer is limited to using substantially two-dimensional metal escutcheons of regular shape. In contrast, by employing the teachings of the present invention, a designer is not limited in the choice of shapes. For example, a designer may choose to use an animal-shaped escutcheon where the corresponding valve handle(s) (especially outer valve handle(s) of the present invention) are located at the “eye” or “limb” of the animal shape. The shape can be implemented in an irregular outline (such as an outline of an animal) as well as in a varying thickness of the escutcheon giving the escutcheon a three-dimensional form. Further, it is a relatively simple matter to differentially color an escutcheon of the present invention, especially when painted or made of a clay-like material.

An escutcheon of the present invention is generally of any desired outline and is provided with at least one hole configured to allow a component or components of the shower fixture to protrude. In embodiments of an escutcheon of the present invention configured for use with a shower fixture provided with a pressure balancing valve, the escutcheon is provided with a hole allowing attachment of a valve handle to the valve therethrough. In embodiments of an escutcheon of the present invention configured for use with a shower fixture provided with two or more stem valves, the escutcheon is provided with sufficient holes allowing the stems of the stem valves to protrude therethrough and thus allowing attachment of the shower valve handles. In some embodiments, an escutcheon of the present invention is provided with a hole configured to allow the hose of a hand-shower to protrude therethrough. In some embodiments, an escutcheon of the present invention is provided with a hole configured to allow a diverter knob to protrude therethrough.

In FIGS. 2A, 2B and 2C is seen a seal-shaped escutcheon of the present invention substantially made of a layer of molded green polyester having a flat back surface and a varying thickness. The varying thickness follows the contours of the seal shape, giving the seal shape a three-dimensional appearance. On top of the molded green polyester is a 5 mm thick layer of clear epoxy in which gravel and reflective flakes are suspended.

Unlike prior art escutcheons made by stamping sheet metal, an escutcheon of the present invention is made by any method that is suitable for a given material from which the escutcheon is made. As discussed hereinbelow, the two preferred methods of making an escutcheon of the present invention are molding and carving. Escutcheon 32 depicted in FIGS. 2A, 2B and 2C is made of two molded layers.

Unlike prior art escutcheons made of metal, an escutcheon of the present invention comprises potentially many different materials including but not limited to acrylic, cement, ceramics, clay, elastomers, enamels, epoxies, foams, glasses, glass-ceramics, gravel, gypsum, marble, mortar, paper, recycled paper, plaster, plastics, polyacrylates, polycarbonates, polyester, polymers, polystyrene, polyurethane, polyvinyl chlorides rubber, silicon rubber, silicon oxide, sponge, stone, styrofoam, terra cotta, rubber, wood, plywood and wood products. In embodiments of the present invention, an escutcheon of the present invention is substantially a unitary structure made of one material.

In other embodiments, an escutcheon of the present invention is made up of a number of different materials, for example, as a plurality of layers or as a coated structure. In a preferred embodiment, an escutcheon of the present invention is made of two or more layers allowing different material properties to be combined. It is important to note that an escutcheon of the present invention is not necessarily devoid of any metal parts. Rather, the structural components of an escutcheon of the present invention are made of a non-metal material. In embodiments of the escutcheons of the present invention, some or all decorative elements of an escutcheon of the present invention include metal. In a preferred embodiment, an outer of two or more layers is transparent. Such a two-layer construction does not only provide exceptional design freedom, but also allows the use of materials heretofore unknown for fashioning escutcheons. For example, in FIG. 2A, escutcheon 32 is made of two layers, a relatively cheap, easily colored and molded polyester as an inner layer and a more durable yet expensive transparent epoxy layer.

In embodiments of the present invention, an escutcheon is coated with a coating. A specific coating is chosen to suit the material from which the escutcheon is made and to provide the escutcheon with desired properties or a desired appearance. Suitable coatings include, but are not limited to, enamels, epoxies, glasses, lacquers, paints, plastics, polymers, shellac, stains. Preferably, coatings with which an escutcheon of the present invention is coated are water-resistant coatings.

In embodiments of the present invention, an escutcheon comprises a material that is fluorescent, phosphorescent or reflective. The material may be either or both the material from which the escutcheon is made or a coating on the material. Such embodiments are an exceptionally useful safety feature, especially in the event of a power outage or for persons desiring to make use of an unlit or otherwise dark shower cabin. In the case of a fluorescent material, it is preferred that the shower cabin in which the escutcheon is installed also include a source of ultraviolet light.

In embodiments of the present invention, at least part of an escutcheon is transparent. In a preferred embodiment, an escutcheon comprises at least two layers, where the uppermost of the layers is transparent. In a preferred embodiment, there is a solid object or many solid objects suspended or held inside the transparent part of the escutcheon. Suitable solid objects include but are not limited to animal products (e.g., coral, feathers, insects, leather, shells, skeletons, spines, teeth), plant products. (e.g., bark, fruit, leaves, pits, roots, twigs, sawdust, seeds), cloth, fabric, flakes, grains, gravel, metal, paper, particles, pebbles, sand, stones, strips and wires. In FIGS. 2A, 2B and 2C, escutcheon 32 is made of two layers, an inner molded green polyester layer and an outer substantially transparent molded epoxy layer in which gravel and reflective flakes are suspended.

In a preferred embodiment of the present invention, the shower trim kit further comprises a switch embedded within the escutcheon, the switch preferably functionally associated with a component that is useful or entertaining. Suitable components include light-emitting components (lamps, light-emitting diodes), motion-producing components (electrical motors) and sound-producing components (music synthesizers, music players). Such embodiments provide an exceptionally useful safety feature, especially in the event of a power outage or for persons desiring to make use of an unlit or otherwise dark shower cabin.

In a preferred embodiment, the switch is functionally associated with a temperature sensor so that the switch toggles between an activated and deactivated state dependent on output from the temperature sensor, e.g., when the temperature in the shower cabin is above a certain predetermined level.

In a preferred embodiment, the solid object inside the escutcheon is light-emitting (e.g., light-emitting diode, lamp). Preferably such a light-emitting object is functionally associated with a switch configured to activate and deactivate the light emission of the solid object. In a preferred embodiment the switch is functionally associated with a temperature sensor such as a thermocouple and the switch is configured to activate the light-emitting object when the temperature sensor senses a given range of temperatures.

In FIG. 3 is depicted a side view of a shower cabin where a fixture 35 including two stem valves 36 (only one of which is seen in FIG. 3 due to the side view) on the inside of wall 10. Escutcheon 38 of the present invention covers the gap in wall 10. Two holes through escutcheon 38 allow stems 40 to emerge therethrough functionally associating stem valves 36 with valve handles 18. Escutcheon 38 substantially includes two parts, a transparent acrylic part 42 in which two light-emitting diodes 44 were embedded during molding and an opaque acrylic part 46 in which switch 48 associated with light-emitting diodes 44 and temperature sensor 50 was embedded during molding. Sensor 50 continuously senses the temperature in the shower cabin. When the shower is activated and the temperature in the shower cabin is higher than 50.degree. C., switch 48 activates light-emitting diodes 44 indicating to a person in the shower of the high temperature in the shower cabin.

In FIG. 4 is depicted escutcheon 66 of the present invention, attached to wall 10. Prior art valve handle 18 protrudes through a hole in escutcheon 66. Escutcheon 66 is made of a 1 cm thick molded acrylic colored to resemble marble.

In FIG. 5 is depicted escutcheon 68 of the present invention, attached to wall 10. Prior art valve handle 18 protrudes through a hole in escutcheon 68. Escutcheon 68 is made of a 1 cm thick molded transparent epoxy. Embedded inside escutcheon 68 are wood chips.

In FIGS. 2A, 2B and 2C is seen an outer valve handle 34 of the present invention for a pressure balancing valve made of green polyester covered with a layer of epoxy and shaped as a seal flipper. Dispersed in the epoxy layer are gravel and reflective flecks. As a result outer valve handle 34 matches escutcheon 32.

An outer valve handle of the present invention may comprise many different materials including but not limited to acrylic, cement, ceramics, clay, elastomers, enamels, epoxies, glasses, glass-ceramics, gravel, gypsum, marble, metals, mortar, paper, recycled paper, plaster, plastics, polyacrylates, polycarbonates, polyesters, polymers, polystyrenes, polyurethanes, polyvinyl chlorides, rubber, silicon rubber, silicon oxide, stone, terra cotta, rubber, wood, plywood and wood products. Just as an escutcheon of the present invention, embodiments of an outer valve handle of the present invention are made of substantially of one layer of a material or of two or more layers allowing different material properties to be combined. In a preferred embodiment, an outer of two or more layers is transparent. For example, in FIGS. 2A, 2B and 2C outer valve handle 34 is made of two layers, a relatively cheap, easily colored and molded polyester as an inner layer and a more durable yet expensive transparent epoxy layer.

Just as an escutcheon of the present, invention; embodiments of an outer valve handle of the present invention are coated with a coating. A specific coating is chosen to suit the material from which the outer valve handle is made and to provide the outer valve handle with desired properties or a desired appearance. Suitable coatings include, but are not limited to, enamels, epoxies, glasses, lacquers, paints, physical vapor deposits, plastics, polymers, powder coatings, shellacs, stains and water-resistant coatings. Preferably coatings with which an outer valve handle of the present invention is coated are water-resistant coatings.

In embodiments of the present invention, an outer valve handle comprises a material that is fluorescent, phosphorescent or reflective. Such embodiments are an exceptionally useful safety feature, especially in the event of a power outage or for persons desiring to make use of an unlit or otherwise dark shower cabin. In the case of a fluorescent material, it is preferred that the shower cabin in which the escutcheon is installed also include a source of ultraviolet light.

In embodiments of the present invention, at least part of an outer valve handle is transparent. In a preferred embodiment, an outer valve handle comprises at least two layers, where the uppermost of the layers is transparent. As with an escutcheon of the present invention, in a preferred embodiment there is a solid object or many solid objects suspended or held inside the transparent part of the outer valve handle. Suitable solid objects include but are not limited to animal products (e.g., coral, feathers, insects, leather, shells, skeletons, spines, teeth), plant products (e.g., bark, fruit, leaves, pits, roots, twigs, sawdust, seeds), cloth, fabric, flakes, grains, gravel, metal, paper, particles, pebbles, sand, stones, strips and wires. In FIGS. 2A, 2B and 2C, outer valve handle 34 is made of two layers, an inner molded green polyester layer and an outer substantially transparent molded epoxy layer in which gravel and reflective flakes are suspended.

As noted hereinabove, prior art valve handles of pressure balancing valves are of substantially unitary construction. Replacement or installation of such a valve handle includes replacing or installing the whole handle, including the part that actually interfaces with a respective pressure balancing valve, requiring intervention of a skilled plumber. Unlike prior art valve handles, an outer valve handle of the present invention is part of a shower trim kit and is designed to fit over a valve handle of a pressure balancing valve. Therefore, embodiments of an outer valve handle of the present invention includes a hollowed-out interior volume configured to receive a valve handle of a pressure balancing valve. It is important to note that when implementing the teachings of the present invention, a pressure balancing valve is preferably provided together with a simple and unfinished valve handle specially configured to fit within a hollowed out interior volume of a outer valve handle of a shower trim kit of the present invention. In FIGS. 2B and 2C is seen an embodiment of an outer valve handle 34 of the present invention including a hollowed-out interior volume 52 configured to receive a valve handle 36 of a pressure-balancing valve.

It is generally preferred to provide an outer valve handle of the present invention with a structural feature or to provide an additional component to the shower trim kit to fix the outer valve handle in place over the valve handle. In an embodiment, a shower trim kit of the present invention includes a compressible fixing component configured to apply a force on the valve handle and on the surface of the hollowed-out interior volume of the outer valve handle thus fixing the outer valve handle in place. In FIG. 2B, outer valve handle 34 is fixed in place by a ring-shaped rubber washer 54 resting inside an annular slot 56 on the outer surface of valve handle 36. In FIG. 2C, outer valve handle 34 is fixed in place by a ring-shaped rubber washer 54 resting inside an annular slot 58 on the surface of the hollowed-out interior volume of outer valve handle 34.

Methods of Installing a Shower Trim Kit of the Present Invention

The present invention provides a method of installing components of a shower trim kit, specifically escutcheons and valve handles for pressure-balancing valves.

According to the methods known in the art, stamped metal escutcheons are held in place using screws, bolts or the like, requiring the use of a peripheral seal. Due to the length and lack of rigidity of such a seal, the seal is difficult to put precisely in place, often giving the shower cabin an unprofessional look and providing insufficient sealing that leads to leakage of water into the wall. Further the use of screws to hold a stamped metal plate escutcheon in place may lead to bending or warping of the escutcheon when excessively tightened.

In a first aspect, the method of the present invention is a method of installing an escutcheon over a shower fixture located inside a wall, by providing a non-metal escutcheon having at least one hole therethrough and affixing the escutcheon in place so that a component of the shower fixture (such as a valve handle) is accessible through the at least one hole. Unlike prior art methods, the method of the present invention of installing escutcheon cannot bend or warp the escutcheon.

In an embodiment of the present invention, the escutcheon-is affixed to a wall by sticking the escutcheon to the wall using, for example, an adhesive, adhesive tape, caulk, polymerizable materials, sealant-or silicon rubber. In FIG. 2C, escutcheon 32 is affixed to wall 10 using double sided adhesive tape 60. In FIG. 3, escutcheon 38 is affixed to wall 10 using silicon rubber 62.

In an embodiment of the present invention, the escutcheon is affixed in place by friction. The escutcheon is placed so that a part of the shower fixture protrudes through a hole in the escutcheon and an elastic holding member (e.g. a ring-shaped member such as a rubber O-ring) is snugly placed about the protruding part of the shower fixture so as to press the escutcheon in place against the wall. In FIG. 2B, a part of a pressure balancing valve surrounded by valve trim 30 protrudes through a hole in escutcheon 32. A rubber O-ring 64 is snugly rolled over valve trim 30 and presses against-escutcheon 32, holding escutcheon 32 in place against wall 10.

In a second aspect, the method of the present invention is a method of installing an outer valve handle over a valve handle of a pressure balancing valve located inside a wall, by providing an outer valve handle configured to fit over the valve handle (such as an outer valve handle of the present invention) and placing the outer, valve handle over the valve handle, for example by pushing the outer valve handle over the valve handle.

Details of installation of an outer valve handle according to the present invention are clear to one of average skill in the art upon perusal of the description and figures, especially FIGS. 2B and 2C,

The method of the present invention is exceptionally useful in the field of plumbing and construction. For example, in a large apartment block or a hotel under construction, shower fixtures with associated valve handles (such as valve handles 36 in FIGS. 2B and 2C) are installed efficiently en masse by a skilled plumber. Subsequently and even at a significantly later date, a desired escutcheon and/or outer handle is custom fit under supervision-of an interior designer. In such a way, installation of a custom escutcheon and valve handles is performed cheaply and efficiently. Further, it is possible to change a given escutcheon and/or outer valve handle at a later date as desired.

Methods of Manufacture of an Escutcheon of the Present Invention

An escutcheon of the is produced using any suitable method known in the art. Suitable methods include methods that employ one or more techniques including, but not limited to, carving, casting, injection-molding, and molding and are generally determined by the type of the material from which an escutcheon is made.

The preferred methods of producing an escutcheon of the present invention include molding techniques and carving, techniques. Molding allows many different and desirable surface features, shapes and textures to be designed and applied to a escutcheon of the present invention and also allows an escutcheon having three-dimensional features to be fashioned.

Generally, an escutcheon of the present invention having a hole therethrough is made by providing a moldable precursor material and placing the moldable precursor material in an escutcheon-shaped mold. The shape and any features in the mold are fixed in the moldable precursor material so as to fashion an incipient escutcheon. After any further required processing of the incipient escutcheon (which may be limited to simply separating the template from the escutcheon), the escutcheon of the present invention is complete.

In embodiments of the present invention, the escutcheon-shaped mold includes a part that corresponds to the hole of the escutcheon. In embodiments of the present invention, subsequent to the fixing of the moldable precursor material, a hole is made in the incipient escutcheon, for example by boring, drilling or trephining.

Moldable precursor materials are generally precursors of materials listed above as being suitable for fashioning a escutcheon of the present invention by molding. Generally, a moldable precursor material is a reversibly deformable before setting, that is a material that is capable of recovering shape after deformation and includes but is not limited to fluids, liquids, powders, foams, polymerizable materials and thermoplastic materials.

Generally, once the moldable precursor material fills the escutcheon-shaped mold, the precursor material must be fixed so as to become solid. Depending on the identity of the moldable precursor material, fixing includes, but is not limited to, methods such as heating the precursor material, cooling the precursor material, curing the precursor material, polymerizing the precursor material, cooling the precursor material, irradiating the precursor material, illuminating the precursor material, exposing the precursor material to a fixative and waiting a period of time. By fixative is meant an agent that causes the precursor material to change to the fixed state and is used herein as a general term for such materials as fixatives, hardeners, polymerization/crosslinking/curing initiators, catalysts and agents. It is important to note that in some cases a precursor material is produced by mixing two or more components which thereafter change to a fixed state, for example, by simply waiting a period of time.

In a preferred embodiment, the moldable precursor material includes a thermoplastic material at plastic temperature and the fixing comprises cooling the thermoplastic material, for example as part of a thermoforming process.

In another preferred embodiment, the moldable precursor material is a polymerizable material (e.g., a monomer solution, a crosslinkable polymer, a vulcanizable polymers, a polymerizable fluids or a thermosetting resin). The polymerizable material is polymerized, fixing the precursor material and thus making the incipient escutcheon.

Processing an incipient escutcheon generally includes giving the incipient escutcheon a final shape. Such processing includes adding a hole in the incipient escutcheon, as discussed above. Such processing also optionally includes treating the surface to modify or change the texture of the escutcheon surface, for example by abrading, brushing, polishing, sand blasting or sanding the surface. Such processing also optionally includes coating the outer surfaces of the incipient escutcheon by methods including but not limited to coloring, lacquering, painting, shellacing spraying, staining and varnishing.

In a preferred embodiment, an additional, preferably decorative, material is added the the moldable precursor material prior to fixing. Examples of suitable additional materials include animal products (e.g., coral, feathers, insects, leather, shells, skeletons, spines and teeth), plant products (e.g., bark, fruit, leaves, needles, pits, roots, twigs, sawdust and seeds), as well as cloth, fabric, flakes, grains, gravel, metal, paper, particles, pebbles, sand, stones, strips and wires. Such adding is most advantageously performed when the escutcheon is transparent subsequent to fixing allowing the added material to be seen.

As the technical details of the techniques recited above are well known, one skilled in the art is able to implement the teachings of the present invention subsequent to perusal of the specification. That said, in a specific example, a model of the escutcheon is made, for example, in wood or plastic by carving or using computer-aided design methods. The model is then transferred to a vacuum forming device to produce a mold of the escutcheon. When the vacuum-formed mold is complete, the moldable precursor material is poured into the mold to produce an escutcheon of the present invention.

An escutcheon 32 of FIG. 2A was made in a manner substantially as described above. A pine wood board was carved by a craftsman using standard wood-carving tools to produce a first seal-shaped escutcheon and a second smaller seal-shaped escutcheon. Both wooden escutcheons were transferred to a vacuum forming device and two polyvinyl chloride molds were made using standard vacuum forming techniques. Gravel (0.5% by weight) and reflective Mylar® flecks (0.1% by weight) were stirred into epoxy resin (RP-055, MCM polymers, Bat Yam, Israel) including 25% by weight hardener and poured into the first larger mold so as to provide a roughly 5 mm thick layer of epoxy in the mold. The second smaller mold was placed in the first mold so as to produce the features of the mold in the epoxy resin. After about 10 minutes during which the epoxy substantially hardened, the second smaller mold was removed and polyester resin (S157 AC7, MCM polymers, Bat Yam, Israel) including 2% hardener and green color (AC-EG, U.S. Composites, West Palm Beach, Fla., USA) was poured over the epoxy layer. After 30 minutes the two layered escutcheon was removed and allowed to harden overnight. Using a standard drill, holes were bored for hose 16, valve handle 18 and diverter knob 20.

An additional preferred method of the present invention is useful in making a escutcheon of the present invention from relatively soft workable materials such as paper, recycled paper, paper mache, wood, and wood products such as plywood. The material is first made into the desired shape, for example by carving or lathing. If desired, surface features, textures and patterns are applied. The incipient escutcheon thus made is then optionally processed further, for example, by sanding, staining, coating or painting. The incipient escutcheon is then impregnated or coated with epoxy, polyester or other water resistant or water repellent material.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.

Claims

1. A shower trim component for installation with a shower fixture, the shower trim component comprising:

an escutcheon for the shower fixture;

said escutcheon formed of a material selected from the group consisting of glass, gravel, marble, paper, stone, wood and wood products.

2. The shower trim component according to claim 1, wherein said escutcheon further comprises a water resistant coating layer on said material.

3. The shower trim component according to claim 1, further comprising an electric component embedded within said escutcheon.

4. The shower trim component according to claim 3, wherein said electric component is a temperature sensor functionally associated with a switch, wherein said switch is configured to toggle between an activated and deactivated state dependent on output from said temperature sensor.

5. The shower trim component according to claim 3, wherein said electric component is functionally associated with a switch, and said electric component is selected from the group consisting of light emitting components, motion producing components and sound producing components.

6. The shower trim component according to claim 1, wherein said escutcheon is coated with a decorative coating.

7. The shower trim component according to claim 6, wherein at least a portion of said escutcheon comprises a material having a property selected from the group consisting of fluorescence, phosphorescence and reflectivity.

8. The shower trim component according to claim 1, wherein a shape of said escutcheon is implemented in an irregular outline.

9. The shower trim component according to claim 4, wherein a shape of said escutcheon is implemented in an irregular outline.

10. The shower trim component according to claim 1, wherein said escutcheon is formed in a shape of an animal.

11. The shower trim component according to claim 4, wherein said escutcheon is formed in a shape of an animal.

12. A shower trim component for installation with a shower fixture, the shower trim component comprising:

an escutcheon for the shower fixture; and

a temperature sensor embedded in said escutcheon operationally coupled to an electric component and configured to activate and deactivate the electric component dependent on output from said temperature sensor.

13. The shower trim component according to claim 12, wherein said component is selected from the group consisting of light emitting components, motion producing components and sound producing components.

14. The shower trim component according to claim 12, wherein said escutcheon includes a transparent resin layer.

15. The shower trim component according to claim 12, wherein a shape of said escutcheon is implemented in an irregular outline.

16. The shower trim component according to claim 12, wherein said escutcheon is formed in a shape of an animal.

17. The shower trim component according to claim 12, wherein at least a portion of said escutcheon comprises a material having a property selected from the group consisting of fluorescence, phosphorescence and reflectivity.

18. A shower trim component for installation with a shower fixture, the shower trim component comprising:

an escutcheon for the shower fixture;

wherein a shape of said escutcheon is implemented in an irregular outline.

19. The shower trim component according to claim 18, wherein said escutcheon is formed in a shape of an animal.