AU606480B2 - Flexi tray - Google Patents

Description

COMMONWEALTH OF AUSTRALIA PATENT ACT 1952 COMPLETE SPECIFICATION (ORIGINAL) S

A

FOR OFFICE USE CLASS INT. CLASS 0094 000 040 0 Application Number: Lodged: Complete Specification Lodged: Accepted: Published: Priority: Related Arc: This document contains the amendments made ufnder S L'tion 4007J iz rcct ii'cr

I

Go 0 4 SLI NAME OF APPLICANT: FLEXITRAY AUSTRALIA PTY. LTD.

ADDRESS OF APPLICANT: 60 GLENAIR STREET, LOWER TEMPLESTOWE, 3107 In the State of Victoria, Commonwealth of Australia NAME(S) OF INVENTOR(S) ALAN EDWARD WYATT ADDRESS FOR SERVICE: DAVIES COLLISON, Patent Attorneys 1 Little Collins Street, Melbourne, 3000.

COMPLETE SPECIFICATION FOR THE INVENTION ENTITLED: FLEXI TRAY The following statement is a full description of this invention, including the best method of performing it known to us -1l. 1 2 3 4 6 7 8 9 11 12 13 .o 14 S 16 9 a 18 19 S 21 0 la METHOD FORMING A WET AREA This invention relates to a method forming a wet area, such as a shower base.

Customarily, shower bases or similar structures defining so called "wet areas" are formed from pre-formed components which are transported to the site required and then positioned and secured in place. These structures may be formed in a variety of ways, such as from pressed metal, from moulded sheet plastics, or from cast materials such as cast concrete. The securement of the structures in position causes difficulty. Special care is needed to ensure that they are securely fixed and that joins to other building parts, such as floors, walls or the like, are waterproof.

Extensive use is made, in the latter regard, of silicone or like sealants.

em 00*(~ 0 4;

'S.

54m 1C n i

I

900620,KXLDAT.020, 25650.88.1 r^ -2- The conventional structures are inconvenient to handle and may be bulky and heavy. Further, the structures are usually available in a limited range of styles or sizes and may not best suit or fit into an existing space in the building.

An object of the invention is to be provide a method of forming a wet area at least in part overcomes the above difficulties.

In one aspect, the invention comprises a method of in situ forming a wet area over an existing surface having an upstanding step structure, comprising the following steps performed in the following order: a) covering the surface within the step structure, and the step structure, with fibreglass material, 15 b) coating the fibreglass material with settable polymer material, c) curing said polymer material whereby there is formed over said step structure, and on the part of said surface therewithin, a waterproof coating.

Preferably the step structure comprises a rim structure.

4 Preferably the wet area comprises a shower base.

With a construction of the above kind it is a simple matter to lay the 25 fibreglass material such as in the form of matting so as to ensure that a satisfactory waterproof coating is achieved whilst at the same time ensuring good waterproofing of edges of the so formed wet area. The invention also provides a wet area formed by the above described method, wherein the wet area is preferably formed as one piece.

leN\p f 901015,edspcMD9,25650J.cJ S-3 -3- The invention is further described by way of example only with reference to the accompanying drawings in which: Figures 1 to 4 are transverse cross sections illustrating steps in the formation of a wet area, more particularly being a shower base in accordance with the method of the invention; Figures 5, 6 and 7 are plan views illustrating steps in the construction of the shower base and corresponding to the steps illustrated, respectively, in Figures 1, 2 and 4; and Figure 8 is a vertical cross section of a second form of shower base constructed in accordance with the invention.

Figures 1 and 5 show a step structure 10 formed on a floor 12 which floor, such as a wooden floor, is supported the bearers 14. The step structure 10 may be formed as desired, such as from the three pieces of timber 16 shows where the step structure is thus of "U"-shaped configuration and is formed against a wall 18 In l this case the step structure is in the form of an upstanding rim structure. Structure 10 is secured to floor 12 in any suitable way such as by nailing.

Following installation of the step structure, a piece of fibreglass matting is laid over this, and over the part of the floor 12 contained therewithin and up against the wall 18 adjacent to the structure 10. The matting is also laid so as to extend over the structure 10 and then some part way along the floor 12 outside the boundary of the structure, as shown in Figure 2 and 6.

,N sN.

E TV V SPAI 901016,cldsp«.9,25650.sp,2 Following positioning of the matting 20, the matting is covered with a suitable settable polymer material and allowed to set to form a coating 22 thereover. Several coatings maybe employed. For example it has been found convenient to provide a preliminary coating which, prior to final setting thereof, is coated with a suitable flow coat, which may be pigmented to form a desired colour.

The base 24 so formed is shown in Figure 4, this being completed by laying of a drainage pipe and fitting 26.

TheA4 structure may be formed otherwise than in shown Figure 1. Figure 8 illustrates an alternative arrangement in which theAr-im structure is formed from a raised floor panel 28. In Figure 8, like reference numerals denote like components to those shown in Figures 1 to 7. Here, the matting is laid up the wall 18 to a substantial height, such 000444 as to a height above that of a shower rose 20 extending from the wall. Also, the matting is laid over the part of the floor panel 28 adjacent to the .Ott edge thereof. Further, in this case, the coating 22 is similarly laid over the matting to extend to the same height at least as the matting and also to extend along the panel 28 to the same extent as the matting.

The method of the invention may be readily adapted to forming shower bases or other wet areas as desired. Since thenA structure is formed in situ it may be of any desired configuration adapted to FZ suit space or asthetic requirements.

It has been found sufficient to leave the structure completed after the curing of the coating 22, but it would of course be possible to undertake further finishing, such as by covering the so formed shower base with tiles or the like.

In practising the invention it has been found convenient to use 450g fibreglass chopped strand matting and to employ suitable epoxy resins, such as isophthalic polyester resins.

It has also been found that the fibreglass membrane formed from the cured resin and matting adheres well to most building construction materials employed in wet areas, such as asbestos sheeting, wall boards, cement, brick and timber.

The invention has been described merely by way of example, and many modifications and variations rnlcq bc Amatybe made thereto without departing from the spirit and scope of the invention which includes every novel feature and combination of features as defined in the appended claims.

T-

Claims (9)

1. A method of in situ forming a wet area over an existing surface having an upstanding step structure, comprising the following steps performed in the following order: a) covering the surface within the step structure, and the step structure, with fibreglass material, b) coating the fibreglass material with settable polymer material, c) curing said polymer material whereby there is formed over said step 1 structure, and on the part of said surface therewithin, a waterproof coating.

2. A method as claimed in claim 1 wherein said upstanding step structure comprises a rim structure.

3. A method as claimed in claim 1 or claim 2 wherein the wet area comprises a shower base.

4. A method as claimed in any one of claims 1 to 3 wherein said fibreglass material comprises fibreglass matting.

I s A method as claimed in any one of claims 1 to 4 wherein said settable material comprises isophthalic material.

6. A wet area formed by the method of any one of claims 1 to

7. A wet area as claimed in claim 6 wherein the wet area is formed as one piece.

8. A method of in situ forming a wet area substantially as hereinbefore described with reference to the accompanying drawings. 901016,edspc.009,25650.spc,6 -7

9. A wet area substantially as hercinbefore describcd with reference to the accompanying drawings. DATED this 15th day of October, 1990. FLEXITRAY AUSTRALIA PTY. LTD. By their Patents Attorneys DAVIES COLLISON III a'' 901015,e1&pcDW),25W5.,? L~r~