AU2012100819A4 - Shower Base - Google Patents

Abstract

2012100819 A shower base or the like formed of a plurality of planar parts of a solid material to form a draining base with a primary planar element mounted at an angle to form a draining angle leading to a drainage port. The solid material can be reconstituted marble material. The solid material can be cuttable. The primary sheet element can be formed of a plurality of sheet elements located in a coplanar configuration. The plurality of planar parts can be a plurality of first, second and third set of substantially planar parts, wherein the first set of substantially planar parts comprise substantially planar sheets forming a top standing surface, the second set of substantially planar parts form a sump part and the third set of substantially planar parts forming a circumferencing retaining wall extending above the top standing surface.

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION INNOVATION PATENT APPLICANT: Formed Australia Pty Ltd INVENTION TITLE: Shower Base The following statement is a full description of this invention, including the best method of performing it known to me: - -2 SHOWER BASE 5 Field of the Invention This invention relates to a shower base or the like and in particular could be used for a range of drainage means, such as in a "wet room", or other shallow style drainage means. 10 Whilst the invention may be applied to a range of drainage means, for convenience sake it shall be described herein in terms of a shower base. Background to the Invention 15 A shower base is generally a floor surface that has a shaped surface extending from a raised perimeter to a lower level exit port connecting to the plumbing and feeding excess liquid to the drains or to a recycling means. In order to achieve the required contour of the floor to provide suitable drainage it has 20 been a typical technique to use a material such as concrete that can be moulded to required shape and have a covering such as tiles applied in location to form a finished draining surface that is waterproof. Clearly this double action is difficult and time consuming and generally requires 25 expertise. To simplify the matter it has been known to provide a single premoulded shower base that is formed off-site and has the built in top draining surface and a bottom flat mounting surface. However this then restricts the choice of shower base to 30 predetermined shapes and sizes and requires bathrooms and shower rooms to be built to the specification of the predetermined sized shower bases. This often does not allow the maximum efficacy of the space available in large or small or plain or awkward shaped rooms. The creativity and design is severely limited. 35 Accordingly, it is an object of the present invention to overcome or to at least substantially ameliorate one or more of the disadvantages of the prior art or at least provide a viable alternative to the prior art.

-3 Summary of the Invention The present invention provides a shower base or the like formed of a plurality of planar parts of a solid material to form a draining base with a primary planar element mounted at an angle to form a draining angle leading to a drainage port. 5 The solid material can be reconstituted marble material. The solid material can be cuttable. 10 The primary sheet element can be formed of a plurality of sheet elements located in a coplanar configuration. The plurality of planar parts can be a plurality of first, second and third set of substantially planar parts, wherein the first set of substantially planar parts comprise 15 substantially planar sheets forming a top standing surface, the second set of substantially planar parts form a sump part and the third set of substantially planar parts forming a circumferencing retaining wall extending above the top standing surface. 20 The plurality of planar parts can be mounted relative to each other such that each part extends substantially horizontal or at one consistent angle to the horizontal to allow a drainage to the drainage port. The plurality of planar parts can be mounted and sealed relative to each other such 25 that the planar parts form a single drainage surface leading to a drainage port. Preferably the plurality of planar parts are formed from two different thickness planar sheets cut to required size to form the central portion of the shower base and a set of elongated panels configured to interfit to form circumferencing side walls. 30 In accordance with one form of the invention there is provided a method of forming a shower base having a drainage angle to an outlet drainage port that can connect to drainage plumbing including the steps of: providing a plurality of first, second and third set of substantially planar parts, 35 arranging the first set of substantially planar parts comprising one or more substantially planar sheets to form a top standing surface and a mounting edge strip -4 to provide an angle from one end of the one or more substantially planar sheets to the other end; arranging the second set of substantially planar parts to form a sump part at the other end of top standing surface, the sump part having a drainage port at its 5 lowest point; constructing the third set of substantially planar parts to form a circumferencing retaining wall extending above the top standing surface wherein a form a central portion of the shower base and circumferencing side walls creating drainage of the shower base to the outlet drainage port. 10 It is preferred that the method can occur on site. It is further preferred that the arranging the second set of substantially planar parts to form a sump part is 15 Preferably the plurality of planar parts are formed from two different thickness planar sheets cut to required size to form the central portion of the shower base The constructing of the third set of substantially planar parts to form a 20 circumferencing retaining wall extending above the top standing surface. The planar parts can be formed by a set of elongated panels configured to interfit in a "h" configuration to form circumferencing side walls. 25 It can be seen that the invention offers a means of constructing a shower base onsite with allowability of alteration of dimensions while still being able to form a top standing surface leading in a draining arrangement to a lower drainage port. The surround can also be adjusted if the floor is uneven. 30 Shower bases could be formed in a mould (poly-marble shower bases), where the fall, lips (that stop capillary action), drain are all in one. This method is for repeating the same size, but anything outside of the mould sizing needs a new expensive mould to be produced. The edges also need to be rounded so the product can be removed from the mould. 35 Traditional versions can be cut and chemically welded together with a fall. The difficulty in manufacturing in this way is that a square piece is cut into 4 triangles on -5 an angle, then somehow the four pieces must be chemically welded or 'glued' together to join the four pieces like the inverted pitch of a roof, and then clamp this together to make sure everything sticks together. This would cause the production to be extremely difficult and such clamping near impossible. Then you have to create 5 the lips to prevent capillary action which also causes more challenges. It can be seen that the invention overcomes this by using planar parts in an arrangement that requires falling at a single consistent angle to the horizontal. 10 In one form the invention simplifies the placement of a drainage tray to simplify the processes further. To make the drainage area out of one solid piece instead of 3 piece that is currently used. To do away with the cover plate with a smaller drain cover plate (could be a slightly different model). To make the entire drainage area out of one single piece using a universal drainage mould. 15 Brief Description of the Drawings In order that the invention can be more readily understood a specific embodiment will 20 be described by way of non-limiting illustration wherein. Figure 1 is a front perspective view of a shower base in accordance with a first embodiment; Figure 2 is a list of constructional inventory of parts of a version of the first embodiment; 25 Figure 3 is a view of the constructional inventory of parts of a version of the first embodiment of Figure 2; Figures 4 to 9 are front perspective views of sequential constructional steps of the central portion of the shower base in accordance with the first embodiment of Figure 1; 30 Figure 10 is a side view of a portion of shower base of Figure 1; Figures 11 and 12 are diagrammatic and end views of constructional parts of circumferencing side walls; Figure 13 is constructional step of applying circumferencing side walls of Figures 12 and 13 to the central portion of the shower base of Figures 4 to 9. 35 -6 Description of a Preferred Embodiment of the Invention In this preferred embodiment, the invention provides a shower base 10 formed of a plurality of planar parts 11, 12, 13 of a solid material to form a draining base with a primary planar element mounted at an angle to form a draining angle leading to a 5 drainage port 35. As shown by Figure 2, at the site the dimensions of the shower base can be determined. The measurements of the outer shape can be determined and thereby a sheet 15 of required dimensions can be created from predefined configurations. 10 The solid material can be reconstituted marble material. The solid material can be cuttable. The primary sheet element can be formed of a plurality of sheet elements located in a coplanar configuration. Preferably the parts are made from two distinct thicknesses of sheets which are relative to each other such that leaning at shallow 15 angle will still allow closing of side . These can in one form be double the thickness of the other. The plurality of planar parts can be a plurality of first 11, second 12 and third 13 set of substantially planar parts, wherein the first set 11 of substantially planar parts 20 comprise substantially planar sheets forming a top standing surface 31, the second set 12 of substantially planar parts form a sump part 32 and the third set 13 of substantially planar parts forming a circumferencing retaining wall 33 extending above the top standing surface. 25 Step I - The Cutting Sheet Using the determined cutting sheet from the defined dimensions of the shower to be created, choose whether the shower base is either rectangular or square. Enter the finished size of the product. Hit Print to get all information required to cut the material for the S3 shower base. The system therefore is able to determine the expansion or 30 dilation or distortion of one of one or more predefined designs and create the inventory of parts to form the required shower base. Step 2 - Pre cut all the material Using the cutting sheet supplied, cut the solid surface into the sizes listed. This is 35 created from at least two sheets of differing thicknesses. Ensure you make sure you use the right thickness sheet. To help you, there are 2 different cutting sheets, 6mm & 12mm. In addition to this each part is labelled with an alphabetical character and a -7 reconstituted marble or the like such as known under the mark Corain sheet thickness number. For example, a part with marked A6 means that it's part A using 6mm sheet, as J12 means Part J using 12mm sheet. 5 Also, you might want to pre-cut parts G12, H12 & 112 collectively called part The Gih. This part can have parts G12 & 112 cut at around 46mm high. This will cover shower bases up to 2 metres in length or width. The Gih can be trimmed down to the required height with a panel saw. This will speed up the manufacturing process. 10 Step 3 - Constructing the first and second set of parts together to form the central portion of the shower base What you'll need - A work area larger than the final shower base size . Plenty of clamps (100mm apart) 15 - Correct glue that suits the colour of the material of the reconstituted marble or the like such as known under the mark Corain - Panel Saw - Pre cut parts A6 - K12 20 Starting with Part A6 laid flat on a surface that is larger then the total size of the base. Glue and clamp parts B12-1 & B12-2 - Hang part B12-1 about 1-2mm over the edge of part A6. Part B12-2 square on the back edge. Put part C12 on the lower edge of part A6 with the angled part facing up. Also have part C12 slightly hanging over the edge as done in step 2. 25 Now place both part D6 on top of the short side B12, so it drops and rests on part A6 Place part E12 on part C12 with the angled part sifting flush with parts D6 and A6. Now is a good time to put the supplied RFID chip in the base. Place it on the 30 underside of E12 between E12 & A6 at least 10mm in. After the glue has set on the "Drainage" part 32, work out the dimensions including the pieces that over the A6 piece, we are going to trim it back to its intended size. For example, if part A6 is should be 820 x 290mm but it measures 822 x 291mm. 35 First set the panel saw to 821mm, trimming one short side, then set the panel saw to 820 and trim the other side. Then set the panel saw to 290mm and trim the side that has both part C12 & E12. You should get a square clean part like that pictured below.

-8 After trimming the "drainage" area, you will now need to glue parts J12 & K12 together and then glue these parts to the "drainage" part. The quickest way of doing this is to place K12 with the angled side up and place J12 on top of it. After 5 you align everything up, put the glue on and clamp it all down. The plurality of planar parts can be mounted relative to each other such that each part extends substantially horizontal or at one consistent angle to the horizontal to allow a drainage to the drainage port. 10 The plurality of planar parts can be mounted and sealed relative to each other such that the planar parts form a single drainage surface leading to a drainage port. Preferably the plurality of planar parts are formed from two different thickness planar 15 sheets cut to required size to form the central portion of the shower base and a set of elongated panels configured to interfit to form circumferencing side walls. It can be seen that the invention provides a method of forming a shower base having a drainage angle to an outlet drainage port that can connect to drainage plumbing 20 including the steps of: providing a plurality of first, second and third set 11, 12 ,13 of substantially planar parts, arranging the first set of substantially planar parts 11 comprising one or more substantially planar sheets to form a top standing surface 31 and a mounting edge 25 strip to provide an angle from one end of the one or more substantially planar sheets to the other end; arranging the second set 12 of substantially planar parts to form a sump part 32 at the other end of top standing surface, the sump part having a drainage port 35 at its lowest point; 30 constructing the third set 13 of substantially planar parts to form a circumferencing retaining wall 33 extending above the top standing surface wherein to form a central portion of the shower base and circumferencing side walls creating drainage of the shower base to the outlet drainage port 35. 35 -9 Step 4 - Making the circumferencing side walls from the third set of parts The constructing of the third set of substantially planar parts to form a circumferencing retaining wall extending above the top standing surface requires a system to prevent capillary action. 5 The planar parts can be formed by a set of elongated panels configured to interfit in a "h" configuration to form circumferencing side walls. However it is important to make the lips (Gih) that prevent capillary action. Cut three pieces of 12mm solid surface as specified on the cutting sheet. Then either using a router or the panel saw, cut down the pieces described on the cutting sheet. 10 If you have pre cut the Gih's, you will need to adjust the height to suit this bases height. The inside edge of part H12 should meet flush with the highest part of part J12. You will need to reduce the height of parts G12 & 112. You will find the correct heights on your cutting sheet. You will then need to cut the Gih's on a 45o angle 15 and to do the mitre join. Do a dry run of putting the Gih's around the base, clamping the Gih's Finally, cut a hole to suit an 80mm OD stainless steel grate and place part F6 over the "drainage" part to ensure that it fits. Remove part F6 and the stainless steel 20 grate, as they will need to be wrapped to ensure they don't scratch the surface during transportation. While we have described herein a particular embodiment of a shower base, it is further envisaged that other embodiments of the invention could exhibit any number 25 and combination of any one of the features previously described. However, it is to be understood that any variations and modifications can be made without departing from the spirit and scope thereof.

Claims (21)

1. A shower base or the like formed of a plurality of planar parts of a solid material to form a draining base with a primary planar element mounted at an angle to form a draining angle leading to a drainage port. 5

2. The solid material can be reconstituted marble material.

3. The solid material can be cuttable. 10

4. The primary sheet element can be formed of a plurality of sheet elements located in a coplanar configuration.

5. The plurality of planar parts can be a plurality of first, second and third set of substantially planar parts, wherein the first set of substantially planar parts 15 comprise substantially planar sheets forming a top standing surface, the second set of substantially planar parts form a sump part and the third set of substantially planar parts forming a circumferencing retaining wall extending above the top standing surface. 20

6. The plurality of planar parts can be mounted relative to each other such that each part extends substantially horizontal or at one consistent angle to the horizontal to allow a drainage to the drainage port.

7. The plurality of planar parts can be mounted and sealed relative to each other 25 such that the planar parts form a single drainage surface leading to a drainage port.

8. The plurality of planar parts are formed from two different thickness planar sheets cut to required size to form the central portion of the shower base and 30 a set of elongated panels configured to interfit to form circumferencing side walls.

9. A method of forming a shower base having a drainage angle to an outlet drainage port that can connect to drainage plumbing including the steps of: 35 a. providing a plurality of first, second and third set of substantially planar parts, - 11 b. arranging the first set of substantially planar parts comprising one or more substantially planar sheets to form a top standing surface and a mounting edge strip to provide an angle from one end of the one or more substantially planar sheets to the other end; 5 c. arranging the second set of substantially planar parts to form a sump part at the other end of top standing surface, the sump part having a drainage port at its lowest point; d. constructing the third set of substantially planar parts to form a circumferencing retaining wall extending above the top standing 10 surface e. wherein a form a central portion of the shower base and circumferencing side walls creating drainage of the shower base to the outlet drainage port. 15

10. The method can occur on site.

11. The arranging the second set of substantially planar parts to form a sump part is 20

12. The plurality of planar parts are formed from two different thickness planar sheets cut to required size to form the central portion of the shower base

13. The constructing of the third set of substantially planar parts to form a circumferencing retaining wall extending above the top standing surface. 25

14. The planar parts can be formed by a set of elongated panels configured to interfit in a "h" configuration to form circumferencing side walls.

15. A means of constructing a shower base onsite with allowability of alteration of 30 dimensions while still being able to form a top standing surface leading in a draining arrangement to a lower drainage port. The surround can also be adjusted if the floor is uneven.

16. Shower bases could be formed in a mould (poly-marble shower bases), 35 where the fall, lips (that stop capillary action), drain are all in one. This method is for repeating the same size, but anything outside of the mould - 12 sizing needs a new expensive mould to be produced. The edges also need to be rounded so the product can be removed from the mould.

17. Traditional versions can be cut and chemically welded together with a fall. 5 The difficulty in manufacturing in this way is that a square piece is cut into 4 triangles on an angle, then somehow the four pieces must be chemically welded or 'glued' together to join the four pieces like the inverted pitch of a roof, and then clamp this together to make sure everything sticks together. This would cause the production to be extremely difficult and such clamping 10 near impossible. Then you have to create the lips to prevent capillary action which also causes more challenges.

18. Using planar parts in an arrangement that requires falling at a single consistent angle to the horizontal. 15

19. Simplifiying the placement of a drainage tray to simplify the processes further. To make the drainage area out of one solid piece instead of 3 piece that is currently used. To do away with the cover plate with a smaller drain cover plate (could be a slightly different model). To make the entire drainage area 20 out of one single piece using a universal drainage mould.

20. A shower base substantially as hereinbefore described with reference to the drawings. 25

21. A method of forming a shower base substantially as hereinbefore described with reference to the drawings.