AU2010100986B4

AU2010100986B4 - A Shower Base

Info

Publication number: AU2010100986B4
Application number: AU2010100986A
Authority: AU
Inventors: Emmanuel Joseph Charles Corfield
Original assignee: CORFIELD AUSTRALIA Pty Ltd
Current assignee: CORFIELD AUSTRALIA Pty Ltd
Priority date: 2009-10-12
Filing date: 2010-09-08
Publication date: 2011-10-06
Anticipated expiration: 2018-09-08
Also published as: AU2010100986A4; AU2010219341A1

Abstract

Abstract A shower base (1) has an upstanding peripheral portion (3) and an upper sheet-like portion (6) which is integral with, and supported by, lower honeycomb-like structures (7). Each honeycomb like structure (7) has side walls which terminate in lower edges (8). The lower edges (8) are coplanar with lower edges of the peripheral upstanding portion (3). The lower edges of the honeycomb like structures (7) and the lower edges of the peripheral upstanding portion (3) accordingly support the shower(1) on the floor or other substrate on which it is mounted. The shower base (1) is integrally formed from material which is alternatively known as "sheet moulding compound" or "sheet moulding composite". SMC is a ready-to-mould fibre-reinforced polyester material primarily used in compression moulding. It is manufactured by dispersing long stands (greater than one inch in length) of chopped glass fibres on a bath of polyester resin.

Description

Title A Shower Base Field of the invention 5 The present invention relates to bases for shower cubicles and the like. Background of the invention The industry norm for shower bases in Australia for the past twenty to thirty years has been heavy rigid polymarble bases that chip and crack easily due to the material used and 10 environmental factors - extended drought conditions which have resulted in clay movement which subsequently results in house movement. Polymarble bases have been successful due to the perceived strength that is assumed to follow from the weight of the product. 15 Acrylic shower bases have been widely used for the past decade, but due partly to the design they have not become popular across Australia, with the exception of Queensland. Traditional acrylic shower bases were hollow shells that needed to be backfilled to eliminate bounce as the product, although stronger than polymarble, is very flexible. The backfilling required more work and invariably more trouble for tradespeople who were 20 more inclined to use polymarble out of habit. Although far superior to polymarble the acrylic manufacturing process does not allow 100% product consistency and surface finish on mass production. Fibreglass reinforcing and finishing is also done by hand and thus leads to human error. Although acrylic is stronger and more versatile than is polymarble it is a softer material surface so more inclined to scratch. 25 Summary of the invention In contrast, embodiments of the present invention provide a shower base formed from sheet moulding compound, comprising: an upper sheet-like portion; 30 a substantially honeycomb-like structure which: is integral with the sheet-like portion; extends downwards from the sheet-like portion; and has lower edges; a first peripheral side-wall which: - 1is integral with; extends upwards from; and extends around the periphery of, the sheet-like portion; and 5 a second peripheral-side wall which: extends downwards from the first peripheral side-wall; and has a lower edge which is substantially co-planar with the lower edges of the substantially honeycomb-like structure. 10 It is preferred that the upper sheet-like portion is substantially square. Brief description of the drawings Preferred embodiments of the invention are described with reference to the drawings, in which 15 figure 1 is a plan view of a preferred embodiment of the present invention; figure 2 is a projection from below of the embodiment of figure 1; and figure 3 is a cross-sectional view on the line 1-1 of figure 1. Description of preferred embodiments of the invention 20 As is illustrated in figures 1, 2 and 3 a shower base or the like 1 is of a square or other suitable shape in plan view. It has a conventional surface 2 on which the user stands for showering and which is surrounded by a conventional upstanding portion 3. As is illustrated in figure 3, the surface 2 is shaped to facilitate the drainage of water towards a drain hole 4. 25 As is illustrated in figures 2 and 3, the shower base I or the like has an upper sheet-like portion 6 which is integral with, and supported by, structures 7. The structures 7 have side walls which terminate in lower edges 8. The lower edges 8 are coplanar with lower edges of the peripheral upstanding portion 3. The lower edges of the structures 7 and the lower 30 edges of the peripheral upstanding portion 3 accordingly support the shower base or the like I on the floor or other substrate on which it is mounted. The use of the honeycomb-like lower structures results in surprisingly high overall strength with relatively low weight of the shower base or the like structure 1, -2- The shower base or the like 1 is integrally formed from material which is alternatively known as "sheet moulding compound" or "sheet moulding composite", both of which are represented by the acronym "SMC". SMC is a ready-to-mould fibre-reinforced polyester 5 material primarily used in compression moulding. It is manufactured by dispersing long strands (greater than one inch in length) of chopped glass fibres on a bath of polyester resin. While the present invention has been described with reference to a few specific 10 embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims. 15 Throughout this specification, including the claims, the words "comprise", "comprising" and "comprises" are to be taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. 20 In the claims, each dependent claim is to be read as being within the scope of its parent claim or claims, in the sense that a dependent claim is not to be interpreted as infringed unless its parent claims are also infringed. -.3 -

Claims

1. A shower base formed from sheet moulding compound, comprising: an upper sheet-like portion; a substantially honeycomb-like structure which: 5 is integral with the sheet-like portion; extends downwards from the sheet-like portion; and has lower edges; a first peripheral side-wall which: is integral with; 10 extends upwards from; and extends around the periphery of, the sheet-like portion; and a second peripheral-side wall which: extends downwards from the first peripheral side-wall; and 15 has a lower edge which is substantially co-planar with the lower edges of the substantially honeycomb-like structure.

2. A shower base as claimed in any one of the preceding claims in which the upper sheet-like portion is substantially square. 20

3. A shower base as claimed in any one of the preceding claims, substantially as described with reference to the drawings.

4. A shower base substantially as described and as illustrated in the drawings. 25 -4-