AU2021107546A4

AU2021107546A4 - Shower base

Info

Publication number: AU2021107546A4
Application number: AU2021107546A
Authority: AU
Inventors: Osvaldo Leon
Original assignee: Limco Group Pty Ltd
Current assignee: Limco Group Pty Ltd
Priority date: 2017-10-05
Filing date: 2021-09-09
Publication date: 2022-01-06
Anticipated expiration: 2026-10-03
Also published as: AU2018241063B2; AU2018241063A1

Abstract

C:\Inte rwoven\NRPortbl\DCC\PLW\17805827_1.docx-3/10/2018 - 16 ABSTRACT Conventional methods for manually building a tiled shower base are complicated and time consuming. More recently, prefabricated shower bases have been designed to simplify installation. However, conventional prefabricated shower bases still suffer from waterproofing issues. In this context, there is a need for prefabricated shower bases with improved waterproofing properties. A shower base module for constructing a tiled shower is provided, the shower base module comprising: a base portion on which tiles are to be subsequently installed, the base portion comprising a drainage aperture, wherein a top surface of the base portion slopes downwardly towards the drainage aperture and wherein the top surface comprises a plurality of drainage grooves, each groove leading into the drainage aperture; flashing extending upwardly from one or more sides of the base portion. 1/7 2--7

Description

1/7

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SHOWER BASE

[0001] The invention relates to a shower base module for constructing a tiled shower, and methods of constructing a tiled shower using the shower base module.

[0002] Conventional methods for manually building a tiled shower base are complicated and time-consuming. A frame for the shower pan is firstly constructed on the subfloor, typically out of wooden blocks. The frame is carefully filled with mortar, ensuring that the base slopes towards the shower drain, and the mortar is then left to harden overnight. A waterproofing liner is attached on top of the mortar, and a hole cut in the liner to accommodate the shower drain. A further layer of mortar may need to be applied before the tiles can be installed.

[00031 More recently, prefabricated shower bases have been designed to simplify installation and improve the water-resistance of the shower areas. The prefabricated shower base essentially replaces the mortar and liner layers, such that once the prefabricated shower base is installed onto the subfloor of a building and the drainage aperture connected to a drain pipe, the shower area may be tiled directly, without the need to apply mortar.

[0004] However, conventional prefabricated shower bases still suffer from waterproofing issues. Inevitably, cracks will form in the tiled floor due to settling or other movement of the building. Water that seeps through the cracks is captured and contained on the prefabricated shower base. While most of the water will generally drain into the drainage aperture, it has been found that some water can remain pooled at sections of the shower base, promoting rot and mold within the floor. Further, it has been found that the area around the drainage aperture of the prefabricated base is prone to defects and leaks.

[0005] In this context, there is a need for prefabricated shower bases with improved waterproofing properties.

[00061 According to an aspect of the present invention, there is provided a shower base module for constructing a tiled shower, the shower base module comprising:

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a base portion on which tiles are to be subsequently installed, the base portion comprising a drainage aperture, wherein a top surface of the base portion slopes downwardly towards the drainage aperture and wherein the top surface comprises a plurality of drainage grooves, each groove leading into the drainage aperture;

flashing extending upwardly from one or more sides of the base portion.

[00071 The drainage aperture may comprise an elongate aperture.

[0008] The shower base module may comprise an annular aperture.

[0009] The shower base module may further comprise a tray at an underside of the base portion and encompassing the drainage aperture to capture fluid entering the drainage aperture, wherein the tray comprises a drainage port connectable to a drain pipe for draining the captured fluid.

[0010] The shower base module may further comprise a mesh insert positioned across the drainage port of the tray.

[0011] The shower base module may further comprise a drainage channel structure positioned on or within the drainage aperture.

[0012] The top surface of the base portion may further comprise a rebate defined around the drainage aperture for receiving edge portions of the drainage channel structure.

[0013] The drainage channel structure may comprise a plurality of slots or recesses configured to be in fluid communication with adjacent portions of the drainage grooves.

[0014] The shower base module may further comprise a drainage cover plate positioned above or within the drainage channel structure.

[0015] The drainage cover plate may be invertible to provide a tray for receiving one or more tile portions.

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[00161 At least one drainage groove may extend from each edge of the base portion and lead into the drainage aperture.

[00171 The top surface of the base portion may further comprise edge drainage grooves along or adjacent a perimeter of the base portion, wherein the edge drainage grooves lead into at least one of said plurality of drainage grooves.

[0018] Each drainage groove may be between about 5 mm and about 15 mm wide.

[0019] Each drainage groove may be between about 5 mm and about 15 mm deep.

[0020] Each drainage groove may be about 10 mm wide and about 10 mm deep.

[0021] The slope of the top surface of the base portion may be at least about 10 mm/meter.

[0022] The base portion may be formed of a polymeric foam.

[0023] A top and/or bottom surface of the base portion may be lined with a waterproofing membrane.

[0024] One or more side surfaces of the base portion may comprise an elongate slot extending along the side surface for retaining the flashing.

[0025] The shower base module may further comprise mesh positioned over each drainage groove.

[0026] The present invention also provides a method of constructing a tiled shower, comprising:

mounting the shower base module as described to a subfloor of a building, wherein each flashing of the shower base module is positioned flush against a wall;

connecting the drainage aperture of the shower base module to a drain pipe of the building; and

installing tiles onto the base portion of the shower base module.

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[00271 The invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a half portion of a shower base module (shown without drainage fittings) according to one embodiment,

Figure 2 is a close-up view of a side portion of the shower base module of Figure 1;

Figure 3 is a plan view of the half portion of the shower base module of Figure 1;

Figure 4 is a bottom view of the half portion of the shower base module of Figure 1;

Figure 5 is a perspective view of a tray mountable to an underside of a shower base according to one embodiment;

Figure 6 is a perspective view of a drain pipe mount attachable to the tray of Figure 5 according to one embodiment;

Figure 7 is a cross-sectional view across the drainage aperture and drainage fittings of the shower base module according to one embodiment;

Figure 8 is a cross-sectional view showing a cosmetic edge flashing installed on a shower base module according to one embodiment;

Figure 9 is a perspective view of a half portion of a shower base module according to another embodiment;

Figure 10 is a bottom view of the shower base module of Figure 9;

Figure 11 is a perspective view of a tray mountable to an underside of the shower base of Figure 9 according to one embodiment;

Figure 12 is a perspective view of an adaptor attachable to the tray of Figure 11 for changing the diameter of a drainage port of the tray according to one embodiment;

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Figure 13 is a perspective view of a drainage channel structure for the shower base module of Figure 9 according to one embodiment; and

Figure 14 is a partially exploded, cross-sectional view across the drainage aperture and drainage fittings of the shower base module according to one embodiment.

[0028] Figure 1 illustrates half of a shower base module 100 for constructing a tiled shower according to one embodiment. The front half of the shower base module is of a similar configuration and has been cut away in Figure 1 to provide a clearer view of details of the shower base. The shower base module 100 comprises a base portion 2 on which tiles 30 are to be subsequently installed. The base portion 2 comprises a drainage aperture 4 extending through the entire thickness of the base portion. The top surface of the base portion 2 slopes downwardly towards the drainage aperture 4. Further, the top surface of the base portion 2 comprises a plurality of drainage grooves 6, each groove leading into the drainage aperture 4, such that any water contained in these grooves is drained into the drainage aperture. The shower base module 100 further comprises flashing 8 extending upwardly from one or more sides of the base portion 2.

[0029] As shown in the embodiment of Figure 1, the drainage aperture 4 may comprise an elongate aperture. The elongate drainage aperture may extend along and adjacent an edge of the base portion 2. In other embodiments, for example as shown in Figure 9, the drainage aperture 4 may comprise an annular aperture. The annular drainage aperture may be located centrally of the base portion 2. Importantly, regardless of the shape or location of the drainage aperture 4, the top surface of the base portion 2 slopes downwardly towards the drainage aperture. Preferably, the amount of slope is at least about 10 mm/meter.

[0030] The shower base module 100 preferably also comprises a tray 10 at an underside of the base portion 2 to capture fluid entering the drainage aperture 4. The tray 10 is sized and shaped to suit the configuration of the drainage aperture 4, preferably to encompass the entire drainage aperture as well as a portion of the surrounding base material. The tray 10 therefore improves the waterproofing properties of the shower base 100 by capturing all water that flows through the drainage aperture 4 and directing all the water to the drain pipe, even if the base

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portion 2 cracks or fails around the drainage aperture 4. For example, Figure 5 illustrates an elongate tray 12 configured to be positioned at the underside of a base portion 2 and to encompass the entire length of an elongate drainage aperture 4 and a portion of surrounding areas, as shown in Figure 4. Figure 11 similarly illustrates a rectangular tray 12 configured to be positioned at the underside of a base portion 2 to encompass an annular drainage aperture 4 and surrounding areas, as shown in Figure 10.

[0031] The tray 10 may comprise side walls 13 extending upwardly from a base, and a drainage port 12 defined in the base. The drainage port 12 is connectable to a drain pipe of the building (not shown) for draining fluid captured in the tray 10. The diameter of the drainage port 12 maybe about 100 mm for connection to a standard drainage pipe. In some embodiments, the drainage port 12 may be about 50 mm in diameter, or an adaptor such as adaptor 31 shown in Figure 12 may be used to provide a reduced-diameter drainage port 33 of about 50 mm, to allow for connection to 50 mm pipes where the shower is to be installed on an upper storey of a building.

[0032] In some embodiments as illustrated in Figure 5, tray 10 may comprise one or more markings 9 provided on the base of the tray as a template for the installer to form (eg drill) a suitable drainage port 12 during installation. This may be particularly useful for installations on upper storeys of a building, to enable the installer to configure the position of the drainage port during installation to suit the position of the existing drainpipe. In some embodiments as illustrated in Figure 6, a drain pipe mount 15 may be attached to the drainage port 12 to provide coupling means for the drain pipe. In one example, a top portion 17 of the drain pipe mount 15 may be detachable, to sandwich the tray 10 in between the top portion 17 and the rest of the mount 15. Seal 19, formed of a suitable elastomeric material such as rubber or a plastics material, may be provided at this detachable connection to ensure a leak-proof connection between the drain pipe mount 15 and the tray 10. Preferably, the top portion 17 of the mount 15 and the drainage port 12 are sized and configured so that when installed, the top portion 17 is flush with the upper surface of the base of the tray 10.

[0033] The tray 10 is formed of any suitably durable, waterproof and lightweight material, such as a plastics material, eg polyvinyl chloride (PVC), or a corrosion-resistant metal. The tray

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may be mounted to the underside of the base portion 2 via any suitable means, for example using an adhesive. In one embodiment, as illustrated in Figures 7 and 14, cutouts such as slots 11 are provided in the underside of base portion 2 to receive side walls 13 of the tray 10. The side walls may be sealingly attached within the slots 11 using a suitable sealant. In some embodiments, the side walls 13 may be about 10 mm to about 15 mm in height, and may extend about or less than midway into the thickness of the base portion 2 when installed. In other embodiments (not shown), the tray 10 may be mounted by hanging outwardly extending rim portions of the tray onto rebate portions 18 defined around the perimeter of the drainage aperture 4, with the body of the tray extending downwardly through the drainage aperture such that the base of the tray 10 is at the underside of the base portion 2.

[0034] In preferred embodiments, as illustrated in Figures 1 and 9, at least one drainage groove 6 extends from each edge of the base portion 2 to the drainage aperture 4. In some embodiments (not shown) where the shape of the base portion 2 is circular or one or more edges of the base portion 2 is/are curved, a suitable number of drainage grooves are preferably provided extending from the curved edge/circumference of the base portion to the drainage aperture 4. For example, for a circular base portion 2, four drainage grooves 6 may be provided, one in each quadrant of the circle.

[0035] Further, edge drainage grooves 26 are preferably provided along or adjacent a perimeter of the base portion 2. The edge drainage grooves 26 lead into at least one of the drainage grooves 6, to provide a continuous flow path for fluid to drain into the drainage aperture 4. Accordingly, the combination of the sloped top surface, the drainage grooves 6 and the edge drainage grooves 26 helps to ensure that any water that seeps though the overlying tiles and onto the base portion 2 will be directed into the drainage aperture 4 and tray 12 and subsequently into the connected drain pipe, regardless of the location of the leak. It will be appreciated that this prevents water from pooling at sections of the shower base, thereby improving the waterproofing properties of the shower base 100.

[0036] In preferred embodiments, each drainage groove 6, 26 is between about 5 mm and about 15 mm wide. In preferred embodiments, each drainage groove 6, 26 is between about 5 mm and about 15 mm deep. For example, the drainage grooves 6, 26 may be about 10 mm wide

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and about 10 mm deep. In some embodiments, mesh 29 may be provided to cover the drainage grooves 6, 26, to prevent debris from entering the grooves during installation of the shower base, while still allowing water to flow into the grooves in use. The mesh 29 may be formed of any suitable durable, corrosion-resistant mesh material such as fiberglass. In some embodiments, removable tape (not shown) may additionally or alternatively be provided to cover the drainage grooves 6, 26 during installation. The tape may, for example, prevent tile adhesive from entering the grooves 6, 26 while the adhesive is being applied to the base portion 2, and the tape may be removed just prior to positioning the tiles onto the base portion.

[00371 Components of the drainage fittings provided inside drainage aperture 4 in preferred embodiments will now be described in more detail, with reference to Figures 7 and 14. A drainage channel structure 16 is positioned on or within the drainage aperture 4 to define a drainage channel, and is sized and shaped to suit the configuration of the drainage aperture. For example, the channel structure 16 may be elongate to fit within the elongate drainage aperture 4 of Figure 1, or may be annular as shown in Figure 13 tofit within an annular drainage aperture 4. The channel structure 16 is preferably formed of a durable, substantially rigid material to provide support and/or attachment means for mounting other components such as cover plate 24 to the shower base module. For example, the channel structure 16 may be formed of a metal such as aluminum or stainless steel.

[0038] In some embodiments, drainage channel structure 16 is positioned on or within the drainage aperture 4 via outwardly extending edge portions 20 of the channel structure received in rebate 18 defined on the top surface of the base portion 2 around the drainage aperture 4. The channel structure 16 may also comprise upwardly extending flanges 21 to provide a tile positioning guide during installation of tiles 30. The length of the upwardly extending flanges 21 is preferably selected to match the installed height of tiles 30.

[0039] In some embodiments as illustrated in Figure 13, the drainage channel structure 16 may comprise a plurality of slots or recesses 22 on the outwardly extending edge portions 20, configured to be in fluid communication with adjacent portions of the drainage grooves 6. This way, the channel structure 16 does not obstruct the flow of water through the drainage grooves 6 and into the drainage aperture 4.

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[00401 In some embodiments, a drainage cover plate 24 is positioned above or within the drainage channel defined by channel structure 16. The cover plate 24 may comprise grates to allow water to drain through the cover plate. Additionally or alternatively, as illustrated in Figure 7, the cover plate 24 maybe sized to provide a gap 25 between the cover plate 24 and sides of the channel structure 16, to allow water to pass through this gap into the drainage aperture 4. The drainage cover plate 24 may be removably supported on channel structure 16 via cover plate holder 24b, as illustrated in Figure 7. Depending on the length of the channel structure 16, one or more cover plate holders 24b may be provided, spaced apart from each other along the length of the elongate drainage aperture 4 to support the channel structure 16. The ability to remove the cover plate 24 from the cover plate holder 24b allows for the cover plate to be replaced and/or inverted to provide a tile retaining tray, as described in more detail below. In other embodiments, the cover plate 24 and cover plate holder 24b may be integrally formed.

[0041] In other embodiments, the cover plate 24 may be attached via a height-adjustable mechanism such as screw threads 27 provided on the base of the cover plate and the inner surface of the channel structure 16, as illustrated in Figures 13 and 14. The height adjustability allows for the height of the cover plate to match the installed height of tiles 30, so as to provide a substantially flush finished surface.

[0042] The drainage cover plate 24 may be formed of any suitably durable and corrosion resistant material, such as stainless steel or aluminum. In some embodiments, the cover plate 24 may be invertible to provide a tray for receiving and retaining one or more tile portions, to match the surrounding tiled area and thereby provide a continuous tiled shower surface.

[0043] In some embodiments, a mesh insert 14 is positioned across the drainage port 12 of the tray 10, to prevent hair and other debris from entering the connected drain pipe. The mesh insert 14 is accessible by the user for cleaning, for example by lifting cover plate 24 (and cover plate holder 24b if provided). In some embodiments, the mesh insert 14 may be removable for cleaning. Alternatively, the mesh insert may be attached to or integral with drainage channel structure 16.

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[00441 The base portion 2 is preferably formed of a lightweight, waterproof and durable material such as a closed-cell polymeric foam, eg expanded polystyrene foam. The foam material is selected to ensure adequate adhesion to tile adhesive, and thereby to the overlying tiles. To increase water-resistance, one or both of the top and bottom surfaces of the base portion 2 may additionally be lined with a waterproofing membrane. In some embodiments, the waterproof membrane is selected to improve binding to tile adhesive.

[0045] Flashing 8 prevents water contained on the base portion 2 from seeping onto surrounding walls. The flashing 8 also provides a secondary water barrier, for example in case of minor flooding, some volume of water can be temporarily retained within the sink defined by the base portion 2 and the surrounding flashing 8. The number of side surfaces of the base portion 2 which require flashing 8 depends on the intended installation location of the shower base. Generally, flashing 8 should be provided as a barrier between the shower base and any adjacent building walls. Accordingly, flashing 8 is formed of a suitably durable, water-resistant material, such as PVC. An elongate slot 28 may be provided extending along the side surface of the base portion 2 and substantially perpendicular to the side surface of the base portion 2, to retain the flashing 8. Sealant and/or membrane linings such as a silicone membrane may be provided at this connection to ensure a complete, watertight seal between the flashing 8 and slot 28.

[0046] Figure 8 illustrates an optional cosmetic flashing 32 that may be attached to a front edge of the base portion 2, ie where the shower base is not against a wall. The flashing may be formed of a suitably durable, corrosion-resistant material such as stainless steel or aluminum. The cosmetic flashing 32 has an upwardly projecting portion 34 that may be sized to be slightly higher than the installed height of the tiles 30, to provide a small lip 36 that may help to retain water within the shower area. When installed, only a top portion 38 of the cosmetic flashing will be visible at the edge of the shower base.

[00471 The present invention also relates to a method for conveniently constructing a tiled shower using the shower base module 100. In preferred embodiments, the shower base module 100 is mounted to the subfloor of the building. The subfloor refers to the structural flooring layer over which cosmetic flooring such as tiles will be laid. For example, the shower base module 100 may be placed on a concrete slab subfloor, a plywood subfloor, or composite subflooring, such as

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particleboard. The shower base module 100 is positioned such that flashing 8 is flush against the wall studs, with plaster installed over and/or above the flashing 8. The drainage aperture 4 of the shower base module 100 is connected to a drain pipe of the building, for example via the drainage port 12 of tray 10. Tiles or other cosmetic finish may then be installed over the base portion 2 and the walls of the shower area. If tape is provided to protect the drainage grooves 6, 26 during installation, the tape may be removed after tile adhesive is applied to the base portion 2 and before the tiles are positioned onto the base portion.

[0048] Each shower base module 100 may be manufactured to the user's required specifications. Alternatively, multiple different configurations of the present shower base may be manufactured for sale. In this way, the entire shower base module may be prefabricated and fully tested for leaks prior to being sold and installed. It will be appreciated that the modularity of various embodiments of the present shower base facilitates this customization. For example, the number of flashings 8 may be selected depending on the number of surrounding walls of the shower area. The height of the tile positioning flange 21 of drainage channel structure 16 and the height of the upwardly projecting portion 34 on cosmetic flashing 32 may be selected to suit the intended height of the installed tiles. Further, cover plate 24 may be height adjustable, as discussed above, to accommodate different tile heights.

[0049] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.

[0050] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavor to which this specification relates.

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[0051] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims

C:\Inte rwoven\NRPortbl\DCC\PLW\17805827_1.docx-3/10/2018 - 13 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A shower base module for constructing a tiled shower, the shower base module comprising:

flashing extending upwardly from one or more sides of the base portion.

2. The shower base module of claim 1, wherein the drainage aperture comprises an elongate aperture.

3. The shower base module of claim 1, wherein the drainage aperture comprises an annular aperture.

4. The shower base module of any one of the preceding claims, further comprising a tray at an underside of the base portion and encompassing the drainage aperture to capture fluid entering the drainage aperture, wherein the tray comprises a drainage port connectable to a drain pipe for draining the captured fluid.

5. The shower base module of claim 4, further comprising a mesh insert positioned across the drainage port of the tray.

6. The shower base module of any one of the preceding claims, further comprising a drainage channel structure positioned on or within the drainage aperture.

7. The shower base module of claim 6, wherein the top surface of the base portion further comprises a rebate defined around the drainage aperture for receiving edge portions of the drainage channel structure.

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8. The shower base module of claim 6 or 7, wherein the drainage channel structure comprises a plurality of slots or recesses configured to be in fluid communication with adjacent portions of the drainage grooves.

9. The shower base module of any one of claims 6 to 8, further comprising a drainage cover plate positioned above or within the drainage channel structure.

10. The shower base module of claim 9, wherein the drainage cover plate is invertible to provide a tray for receiving one or more tile portions.

11. The shower base module of any one of the preceding claims, wherein at least one drainage groove extends from each edge of the base portion and leads into the drainage aperture.

12. The shower base module of any one of the preceding claims, wherein the top surface of the base portion further comprises edge drainage grooves along or adjacent a perimeter of the base portion, wherein the edge drainage grooves lead into at least one of said plurality of drainage grooves.

13. The shower base module of any one of the preceding claims, wherein each drainage groove is between about 5 mm and about 15 mm wide.

14. The shower base module of any one of the preceding claims, wherein each drainage groove is between about 5 mm and about 15 mm deep.

15. The shower base module of any one of the preceding claims, wherein each drainage groove is about 10 mm wide and about 10 mm deep.

16. The shower base module of any one of the preceding claims, wherein the slope of the top surface of the base portion is at least about 10 mm/meter.

17. The shower base module of any one of the preceding claims, wherein the base portion is formed of a polymeric foam.

18. The shower base module of any one of the preceding claims, wherein a top and/or bottom surface of the base portion is lined with a waterproofing membrane.

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19. The shower base module of any one of the preceding claims, wherein one or more side surfaces of the base portion comprises an elongate slot extending along the side surface for retaining the flashing.

20. The shower base module of any one of the preceding claims, further comprising mesh positioned over each drainage groove.

21. A method of constructing a tiled shower, comprising:

mounting the shower base module of any one of claims 1 to 20 to a subfloor of a building, wherein each flashing of the shower base module is positioned flush against a wall;

installing tiles onto the base portion of the shower base module.