EP3918965A1

EP3918965A1 - Mounting structure for shower trays, method for producing a shower tray and prefabricated shower tray

Info

Publication number: EP3918965A1
Application number: EP20710209.6A
Authority: EP
Inventors: Isidoro GARCIA MARTIN
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-01-28
Filing date: 2020-01-28
Publication date: 2021-12-08
Anticipated expiration: 2040-01-28
Also published as: EP3918965B1; WO2020157356A1; EP3918965C0

Abstract

Prefabricated shower tray, mounting frame, and method of manufacturing a shower tray. The shower tray comprises a top slab and an inner body adhered to the top slab, the top slab being formed from at least four trapezial plates. The method comprises a first step in which the top slab of the shower tray is obtained, and a second step in which the inner body is obtained. In the first step, the trapezial plates are arranged on a mounting frame (100) comprising a perimeter frame (3) housing an end of each trapezial plate. The mounting frame (100) also comprises a bottom support (5) arranged at a lower level of the perimeter frame (3) such that the trapezial plates converge in said bottom support (5), thus defining a camber of the shower tray. The method of the invention also comprises an overturning step which is carried out during the first step so as to have access to a bottom face of the top slab, attaching and sealing the trapezial plates to one another, both by the top face and by the bottom face of the top slab, with these being mounted on the mounting frame (100).

Description

TECHNICAL FIELD

The present invention relates to shower trays and to methods of manufacturing the shower trays, particularly to methods using a mounting frame when mounting the shower tray.

PRIOR ART

The tendency of users in the use of shower trays commonly referred to as extra-flat trays, the thickness of which, measured at one end of the shower tray, for example, is comprised in a range between 20 and 40 mm, has increased in recent years. Shower trays of this type comprise a thin top slab comprising a thickness between 3 and 20 mm, and an inner body adhered to said outer surface which imparts the necessary robustness to the top slab.
Shower trays of this type can be manufactured directly on site, in which case it is necessary and indispensable to create a base in the floor that slope towards a drain point, and to subsequently level and waterproof the floor and walls before the final coating, and the skill of the construction worker is of vital importance in these cases to avoid possible water leakage, or they can be prefabricated so that they can be readily placed in their final location.
There are a number of prefabricated extra-flat shower trays in which the top slab is formed by a flat ceramic sheet that is bent to achieve the necessary camber. A mounting frame in which the sheet is supported and on which heat or pressure is applied for said sheet to adapt to the shape of the mounting frame is known to be used to bend these ceramic sheets.
In this sense, ES2582681 A1 describes a prefabricated extra-flat shower tray comprising a top slab formed by a sintered ceramic sheet and an inner body adhered to said top slab. The ceramic sheet is curved, with the aid of a mounting frame, so as to provide the necessary camber. The mounting frame comprises a perimeter frame and two cross-shaped bars with variable thickness, the perimeter frame being arranged in the lowest position. The ceramic sheet is arranged with its usable surface supported on the mounting frame and its edges are pressed so that they contact the perimeter frame. With the sheet in that arrangement, a layer of resin is applied, which will form the inner body of the shower tray when hardened and will preserve the curved shape of the sheet.

DISCLOSURE OF THE INVENTION

One object of the invention is to provide a mounting frame for shower trays, as defined in the claims.
The mounting frame of the invention is suitable for mounting shower trays of the type comprising a top slab formed from at least four trapezial plates and an inner body adhered to the top slab. The mounting frame comprises a perimeter frame formed by two longitudinal bars and two transverse bars. Both the longitudinal bars and the transverse bars each comprise at least one channeled segment which allows completely or partially housing an end of a corresponding trapezial plate, preferably the widest end. The mounting frame also comprises a bottom support arranged at a lower level of the perimeter frame, such that the trapezial plates converge in said bottom support, thus defining a camber of the shower tray and the final shape of the shower tray such that the assembly mounted on the mounting frame remains compact and secured while acting or working on said assembly.
Another object of the invention is to provide a method of manufacturing a shower tray, as defined in the claims.
The method of manufacture comprises a first step in which the top slab of the shower tray is obtained and a second step in which the inner body is obtained. The top slab is formed from at least four trapezial plates, such that in the first step said trapezial plates are arranged on a mounting frame comprising a perimeter frame completely or partially housing one of the ends of each trapezial plate, preferably the widest end, such that the final shape of the shower tray is obtained. The mounting frame also comprises a bottom support arranged at a lower level of the perimeter frame such that the trapezial plates converge in said bottom support, thus defining a camber of the shower tray. The method of the invention also comprises an overturning step which is carried out during the first step so as to have access to a bottom face of the top slab, attaching and tightly sealing the trapezial plates to one another, both by the top face and by the bottom face of the top slab, with these being mounted on the mounting frame.
The mounting frame and method of manufacture of the invention make it easier to mount the shower trays and reduce the manufacturing time as they mainly improve the first step of the manufacturing process in which the top slab of the shower tray is obtained. As a result of the mounting frame and method of manufacture of the invention, it is possible to obtain a shower tray with the desired camber, regardless of how pronounced it may be, without the risk of the top slab cracking or breaking, and the operation of fixing and sealing the butt joints between trapezial plates is likewise strengthened since said plates remain compact in their position during the manufacturing process for manufacturing the top slab, so the operation of applying the adhesive and/or the sealant between the butt joints can be carried out with guarantees.
Another object of the invention is to provide a prefabricated shower tray, as defined in the claims.
The prefabricated shower tray of the invention comprises a top slab and an inner body adhered to the bottom face of the top slab, the top slab being formed from the attachment and tight sealing of at least four trapezial plates. The shower tray also comprises a central part arranged between the top slab and the inner body, such that the narrowest end of each trapezial plate of the top slab converges in said central part at the lowest part of the top slab, a camber of the shower tray thus being defined, said central part being suitable for cooperating with the drain system of the space or room where the shower tray is going to be placed.
These and other advantages and features of the invention will become apparent in view of the drawings and the detailed description of the invention.

DESCRIPTION OF THE DRAWINGS

Figure 1A shows a perspective view of the shower tray according to one embodiment of the invention.
Figure 1B shows a perspective view of another embodiment of the shower tray of the invention.
Figure 2 shows an exploded view of the shower tray of Figure 1A.
Figure 3 shows a perspective view of the mounting frame of shower trays according to one embodiment of the invention.
Figure 4 shows a perspective view of the mounting frame of Figure 3 but without the bottom support and with the securing bar.
Figure 5 shows a perspective view of the mounting frame of Figure 4 but with the trapezial plates mounted on the mounting frame.
Figure 6 shows a perspective view of the mounting frame of Figure 3 but without the bottom support and with the positioning bars.
Figure 7 shows a perspective view of the mounting frame of Figure 6 but with the trapezial plates arranged in the mounting frame.
Figure 8 shows a perspective view of the mounting frame of Figure 6 but with the additional positioning bar and with the trapezial plates arranged in the mounting frame.
Figure 9 shows an exploded view of another embodiment of the shower tray of the invention.
Figure 10 shows a perspective view of the shower tray of Figure 9 but with the hole made in the top slab.

DETAILED DISCLOSURE OF THE INVENTION

Figure 1A shows a non-limiting example of an embodiment of the prefabricated shower tray 200 of the invention. The shower tray 200 of the invention is of the type commonly referred to as extra-flat and as described in Spanish utility model ES1226914 U , which belongs to the same applicant as the present and is incorporated herein by reference, the shower tray 200 comprises a top slab 1 and an inner body 2 adhered to the bottom face 11 of the top slab 1. The thickness of the top slab 1 is small compared to the inner body 2. The inner body 2 is what imparts strength, i.e., robustness, to the top slab 1, which prevents the latter from readily being able to break in use.
In the preferred embodiment of the invention, the top slab 1 is formed from the attachment and tight sealing of at least four trapezial plates 1 a, as shown in Figures 1A and 2. The shower tray 200 also comprises a central part 6, described in application U 201900509 corresponding to the Spanish utility model, belonging to the same applicant as the present and incorporated herein by reference, arranged between the top slab 1 and the inner body 2, such that the narrowest end of each trapezial plate 1a of the top slab 1 converges in said central part 6 at the lowest part of the top slab 1, a camber of the shower tray 200 thus being defined.
As observed in Figure 2, the central part 6 comprises a base 6a, being preferably rectangular, and a central hole 6c intended for cooperating with the drain system of the space or room where the shower tray 200 is going to be placed. The base 6a and the central hole 6c are attached through a central depression 6b, with the hole 6c being located at the bottom of said central depression 6b. Although the central part 6 is rectangular in the preferred embodiment, other shapes such as, for example, circular, rectangular, polyhedral, oval, or any combination thereof, are not ruled out. The central part 6 is made of metal, preferably stainless steel, although other materials compatible with the invention, such as, for example, plastic, a natural material, or a synthetic material, are not ruled out.
Optionally, in one variant of the shower tray 200 of the invention, instead of the central part 6, the shower tray 200 may comprise an additional central part 6', where said additional central part 6' differs from the previous central part 6 in that it only comprises a base 6a, i.e., it does not comprise the central hole or the central depression, a hole 17 being generated in a subsequent operation so as to allow the coupling with the drain system of the room of the final location of the shower tray 200.
The narrowest ends of each trapezial plate 1a rest on the base 6a, and therefore the central part 6, or the additional central part 6', provides an additional reinforcement to the most delicate area of the shower tray 200, which is precisely the area closest to the drain point, therefore providing great structural stability.
Moreover, another one of the objectives of the central part 6, or the additional central part 6', is to assure the enclosing and sealing of the lowest part of the shower tray 200. As a result of this central part 6, or the additional central part 6', perfect sealing of this area of the shower tray 200 is assured, and the coupling with the drain system of the space of the final location of the shower tray 200 is facilitated, assuring perfect tightness of the shower tray 200 and of the space.
In the preferred embodiment of the invention, each trapezial plate 1a of the top slab 1 comprises a sheet of ceramic material, sintered ceramic material, resin, acrylic, natural stone, or synthetic stone. Optionally, in another embodiment of the shower tray 200 of the invention each trapezial plate 1a of the top slab 1 can be formed from a plurality of floor tiles or tiles which are fixed and sealed to one another, as can be seen in Figure 1B. It is thereby possible to combine the decoration of the floor of the room and of the shower tray 200 such that the final user perceives the sensation of having a continuous floor in the shower or bath. The finishing of a shower tray 200 with floor tiles was until now only possible if the shower tray was manufactured on site, with the difficulties this entails, such that the installation of a shower tray with a floor tile finish is greatly facilitated with the shower tray 200 and the method of manufacture of the invention.
In the preferred embodiment of the invention, the inner body 2 is made up of a material such as a resin or an agglomerate of natural, synthetic, or chemical aggregates mixed with natural, synthetic, or chemical binders.
Optionally, the inner body 2 can be reinforced with a mesh 7, being preferably metallic, although it could also be made of plastic, which is embedded in the inner body 2, as described in detail below.
The inner body 2 may also optionally comprise decorative strips arranged on the periphery such that they cover the entire outer contour of the inner body 2, said decorative strips being made from the same material as the trapezial plates 1a.
The objective of the method of manufacture and the mounting frame 100 of the invention is to facility and improve the manufacture of shower trays 200 such as that described above.
The method of manufacturing the shower trays according to the preferred embodiment of the invention comprises a first step in which the top slab 1 of the shower tray 200 is obtained and a second step in which the inner body 2 is obtained. As already discussed, in the preferred embodiment of the invention the top slab 1 of the shower tray 200 is formed from at least four trapezial plates 1a, such that in the first step said trapezial plates 1a are arranged on a mounting frame 100 comprising a perimeter frame 3 completely or partially housing in its interior one of the ends of each trapezial plate 1a, preferably the widest end, such that the final shape of the shower tray 200, which will usually be rectangular, is obtained, creating an opening 18 in the lowest area of the top slab 1 where the trapezial plates 1a converge. The mounting frame 100 also comprises a bottom support 5 arranged at a lower level of the perimeter frame 3 such that the trapezial plates 1a converge in said bottom support 5, thus defining a camber of the shower tray 200 and the final shape of the shower tray 200. The method of the invention also comprises an overturning step which is carried out during the first step so as to have access to a bottom face 11 of the top slab 1, applying the adhesive and/or sealant for attaching and tightly sealing the trapezial plates 1a to one another, both by the top face 12 and by the bottom face 11 of the top slab 1, with these being mounted on the mounting frame 100. The top face 12 of the top slab 1 corresponds with the usable surface or visible face of the shower tray 200 and the bottom face 11 corresponds with the back of the top face 12 of the trapezial plates 1a.
The perimeter frame 3 of the mounting frame 100 of the preferred embodiment is formed by two longitudinal bars 3a and two transverse bars 3b, each longitudinal 3a and transverse 3b bar comprising at least one channeled segment 4 which allows completely or partially housing an end of a corresponding trapezial plate 1a of the top slab 1, preferably the widest end, as can be seen in Figure 5, for example. As observed in said Figure 5, the end of the trapezial plates 1a housed in the corresponding channeled segment 4 is the widest end of the parallel sides of the trapezium. Optionally, the corresponding channels 4 of the longitudinal bars 3a and transverse bars 3b may comprise in their interior a lining, such as a flexible padded surface for example, so as to not damage the ends of the trapezial plates 1a which are housed in their interior.
In another embodiment of the mounting frame 100 of the invention not shown in the drawings, the longitudinal bars 3a and the transverse bars 3b each comprise two profiles, with the corresponding channel 4 being formed upon attaching said profiles to one another, such that the width of each channel 4 of each bar 3a and 3b is adjustable, the width of each channel 4 being adjusted at the beginning of the first step of the method of the invention to the thickness of the corresponding trapezial plate 1a to be housed in said channel 4.
In the preferred embodiment of the mounting frame 100 of the invention, the transverse bars 3b are slidable along the longitudinal bars 3a, where they can be locked at any point of the longitudinal bars 3a. Likewise, in the preferred embodiment the transverse bars 3b are extendable, where they can also be locked at any point, such that the perimeter frame 3 can be readily coupled to any dimension of the shower tray 200.
In the preferred embodiment of the mounting frame 100 of the invention, at least each transverse bar 3b comprises at each of its ends an anchoring part 13 cooperating with a corresponding longitudinal bar 3a locking the position of said transverse bar 3b, as can be seen in Figure 3, for example. With the anchoring parts 13 in an unlock position, the transverse bars 3b can slide freely along the longitudinal bars 3a, and with the anchoring parts 13 in a lock position, the transverse bars 3b are fixed with respect to the longitudinal bars 3a.
Each transverse bar 3b in the preferred embodiment of the invention comprises a main body 14 and an extension element 14' at each end of the main body 14, with each extension element 14' cooperating with the corresponding longitudinal bar 3a. Each end of the main body 14 of the corresponding transverse bar 3b also comprises a respective anchoring element 13 for fixing the position of the extension elements 14'. In an embodiment not shown in the drawings, the main body 14 and the extension ends 14' can be hollow profiles, for example rectangular hollow profiles, which fit with one another.
The anchoring parts 13 may comprise a system of nuts and bolts so as to be fastened or locked, although they could also comprise similar means, such as for example fasteners or clamps.
With the anchoring parts 13 of the perimeter frame 3 in the unlock position when mounting the trapezial plates 1a in the mounting frame 100, the latter can be readily adjusted by hand in real time, i.e., dynamically, to the dimensions adopted by the trapezial plates 1a in their final position, so the placement of the trapezial plates 1a in the mounting frame 100 at the beginning of the first step of the method of the invention is quite simple and quick.
Before locking the mounting frame 100, the adhesive and/or sealant is applied on the edge of the butt joints between trapezial plates 1a, and then the trapezial plates 1a are joined together, defining the final position. Once the trapezial plates 1a are in their final position and the edges of the butt joints incorporate the adhesive and/or sealant, the anchoring parts 13 of the perimeter frame 3 are locked, keeping said trapezial plates 1a in their position in a compact manner to enable acting or working on them. Once the trapezial plates 1a are locked by the frame 100, the adhesive and/or sealant that may have overflowed is removed.
Therefore, the mounting frame 100 and the method of manufacture of the invention make it easier to mount the shower trays 200 and reduce the manufacturing time as they mainly improve the first step of the manufacturing process in which the top slab 1 of the shower tray 200 is obtained. As a result of the mounting frame 100 and method of manufacture of the invention, is possible to obtain a shower tray 200 with the desired camber, regardless of how pronounced it may be, without the risk of the top slab cracking or breaking, and the operation of fixing and sealing the butt joints between trapezial plates 1a is likewise strengthened since said plates remain compact in their position during the manufacturing process of the top slab 1, so the operation of applying the adhesive and/or the sealant between the butt joints can be carried out with guarantees.
In the preferred embodiment of the invention, the bottom frame 5 of the mounting frame 100 is removable and/or slidable in the longitudinal and transverse direction of the perimeter frame 3 where it can be locked at any point with respect to the perimeter frame 3, for example with anchoring parts 13 similar to those described.
In one embodiment of the invention, the bottom support 5 comprises a support base 5a arranged on a support bar 5' which is arranged between two parallel bars of the perimeter frame 3, preferably the longitudinal bars 3a, in a removable and/or slidable manner, and which, as can be seen in the non-limiting example of Figure 3, comprises two main profiles 15 that can be extended through extension elements 15' arranged at each end of each main profile 15, the support base 5a of the bottom support 5 being arranged between the two main profiles 15 such that the bottom support 5 can move in the transverse direction of the perimeter frame 3. Each end of the support bar 5' may comprise anchoring parts 13 similar to those described above so as to lock the bottom support 5.
In the preferred embodiment of the invention, the bottom support 5 is also height-adjustable with respect to the perimeter frame 3, where it can be moved towards a lower level of the perimeter frame 3. Thus, at the beginning of the first step, and preferably before starting to place the trapezial plates 1a, the position and height of the bottom support 5 are adjusted.
In another embodiment not shown in the drawings, the mounting frame 100 may comprise support legs to raise the perimeter frame 3 with respect to the floor level to prevent the bottom support 5 from colliding. However, if the mounting frame 100 is arranged on a surface with a void or recess such that the bottom support 5 does not collide, it is possible to dispense with said support legs.
Likewise, in the preferred embodiment of the invention the bottom support 5 comprises a housing 5", being preferably circular, which can house a central part 6 of the shower tray 200, for example, such as that described above, such that the central depression 6b of the central part 6 can be housed, centered, and guided in said housing 5".
In the event of the shower tray 200 comprising said central part 6, the narrowest ends of the trapezial plates 1a mounted on the mounting frame 100 converge in said central part 6, being supported on the base 6a of said central part 6. As already discussed above, the central part 6 is the linkage between the shower tray 200 and the drain system of the space where the shower tray 200 is going to be placed, and furthermore imparts great structural stability to the shower tray 200 in said area close to the drain point.
In the first step of the method of the invention, the ends of the trapezial plates 1a which are supported on the plate central 6 and said plate central 6 must also be fixed, for example with an adhesive, and tightly sealed to one another before and after the overturning step, i.e., they must be fixed and sealed both by the top face 11 of the top slab 1 and by the bottom face 12.
When acting on the bottom face 11 of the top slab 1, the fact that the bottom support 5 is removable may be particularly advantageous so as to not hinder the operator's work on said bottom face 11, in which case it is advisable to dismantle the bottom support 5 before the overturning step.
The mounting frame 100 of the invention allows turning over the entire assembly mounted in said mounting frame 100 so as to allow work to continue on the bottom face 11 of the top slab 1, while this is still being mounted in the mounting frame 100. The fact that the entire assembly mounted in the mounting frame 100 can be turned over in bloc is particularly advantageous since it is possible to continue working on the bottom face 11 of the top slab 1 even when the adhesive and/or sealant applied on the top face 12 has not yet dried or cured, so the manufacturing time of the shower tray 200 is extremely reduced.
To that end, the mounting frame 100 comprises a securing bar 8, such as that shown in Figure 4, which is arranged between two parallel bars 3a or 3b of the perimeter frame 3, preferably the longitudinal bars 3a, in a removable and/or slidable manner before the overturning step. Said bar 8 comprises a top retaining element 9 suitable for being supported simultaneously on the narrowest ends of the trapezial plates 1a, and a bottom retaining element 9' suitable for securing the narrowest ends of the trapezial plates 1a by the bottom portion of the top slab 1, with the narrowest ends of the trapezial plates 1a being retained by the top retaining element 9 and the bottom retaining element 9'. Thus, the trapezial plates 1a are secured through the securing bar 8 and the perimeter frame 3, maintaining their position, such that the assembly mounted on the mounting frame 100 can be turned over, i.e., manipulated, during the overturning step so as to allow work to continue on the bottom face 11 of the top slab 1 without having to take the mounted assembly apart.
In the preferred embodiment of the invention, the securing bar 8 is extendable to enable being adjusted to the dimensions of the perimeter frame 3. Likewise, each end of the securing bar 8 may comprise an anchoring part 13, such as those described above, which cooperates with a corresponding bar 3a or 3b of the perimeter frame 3, so as to lock its position. Like the transverse bars 3b, in a non-limiting example the securing bar 8 may comprise a main body 8' and an extension element 8" at each end of the main body 8' such that the adjustment of the securing bar 8 is similar to the adjustment of a transverse bar 3b.
The top retaining element 9 of the securing bar 8 is height-adjustable. In the preferred embodiment of the invention, the securing bar 8 comprises a threaded rod 9" going through the top slab 1 through the opening 18 existing close to the drain point of the shower tray 200, i.e., close to the area of attachment of the narrowest ends of the trapezial plates 1a. The top retaining element 9 comprises a base, being preferably square, with a surface such that it is capable of encompassing part of the narrowest end of each trapezial profile 1a, as can be seen in Figure 5, and comprising a threaded central hole cooperating with the threaded rod such that said top retaining element 9 can be readily brought closer to the surface of the top slab 1, its position being fixed. The bottom retaining element 9' can be similar to the top retaining element 9, i.e., it may comprise a base with a threaded hole also cooperating with the threaded rod of the securing bar 8. In this case, the bottom retaining element 9' acts as if it were a nut.
Before placing the securing bar 8 on the perimeter frame 3, it is advisable for the top retaining element 9 to be arranged on the threaded rod 9". In contrast, the bottom retaining element 9' is placed by being threaded onto the threaded rod 9" on the bottom face 11 of the top slab 1.
In the event that the shower tray 200 comprises the central part 6, the bottom retaining element 9' may vary since in this case it would be sufficient for said bottom retaining element 9' to encompass part of the central part 6. Therefore, in another embodiment of the invention the base of the bottom retaining element 9' is circular.
Optionally, in one variant of the invention the mounting frame 100 of the invention may comprise at least one positioning bar 10 such as that shown in Figure 6, for example, also arranged, like the securing bar 8, between two parallel bars 3a or 3b of the perimeter frame 3, preferably the longitudinal bars 3b, in a removable and/or slidable manner such that it can be locked at any point of the perimeter frame 3.
In the preferred embodiment of the invention, the positioning bar 10 is extendable to enable being adjusted to the dimensions of the perimeter frame 3. Likewise, each end of the positioning bar 10 may comprise an anchoring part 13, such as those described above, which cooperates with a corresponding bar 3a or 3b of the perimeter frame 3, so as to lock its position. Like the transverse bars 3b or the securing bar 8, the positioning bar 10 comprises a main body 16 and an extension element 16' at each end of the main body 16 such that the adjustment of the positioning bar 10 is similar to the adjustment of a transverse bar 3b or to the adjustment of the securing bar 8.
Moreover, as can be seen in Figure 6, the positioning bar 10 comprises a plurality of stops 10' arranged on the top portion and bottom portion of the perimeter frame 3, preferably at least four in each of the portions, which are suitable for being supported on the bottom face 11 and the top face 12 of the top slab 1 such that the positioning bar 9 keeps the assembly mounted in the mounting frame 100 aligned, which is of interest for the overturning step; therefore, it is advisable to place both the securing bar 8 and the positioning bar 10 before the overturning step, where the positioning bar 10 can be placed before or after placing the securing bar 8.
Likewise, the mounting frame 100 may comprise more than one positioning bar 10. In the event of the mounting frame 100 comprising a single positioning bar 10, it is advisable to arrange the latter on the side where the distance, in the longitudinal direction of the mounting frame 100, between the position of the bottom support 5 and an end of the perimeter frame 3 is greater. In contrast, if the mounting frame 100 comprises a plurality of positioning bars 10 it is advisable to distribute said positioning bars 10 on both sides of the position of the bottom support 5.
In the preferred embodiment of the invention, each stop 10' of a respective positioning bar 10 is movable on the bar 10 itself such that two consecutive stops 10' of one and the same bar 10 can be arranged on each side of the butt joint between two adjacent trapezial plates 1a, as can be seen in Figure 7; the closer to the corresponding joint the better.
In the preferred embodiment of the invention, each stop 10' is height-adjustable. In a non-limiting example, said stop 10' comprises a threaded rod, for example a bolt, moving in a respective threaded hole of the corresponding positioning bar 10 to approach or move away from the trapezial plates 1a.
As a result of the positioning bars 10 and the securing bar 8, it is possible to manipulate the assembly of trapezial plates 1a mounted on the mounting frame 100, with or without the central part 6, assuring at all times linearity between plates 1a, even if no adhesive has been applied, or even after having applied adhesive and/or sealant and it has not yet hardened or cured. Therefore, as already discussed above, the manufacturing time of the shower tray 200 is drastically reduced.
Continuing with the method of the invention, once the adhesive and/or sealant has been applied on the top face 11 of the top slab 1 and/or on the central part 6, the bottom support 5 is optionally dismantled, the securing bar 8 is placed, and preferably a plurality of positioning bars 10 is also placed, and then the mounting frame 100 is turned or turned over so as to have access to the bottom face 12 of the top slab 1. The turning can be done by hand or the mounting frame 100 could be arranged such that it can pivot about a longitudinal axis passing through the center of the transverse bars 3b.
On the bottom face 11, since it is the non-visible face of the shower tray 200, it is possible to apply the adhesive as described below to even further strengthen the attachment between trapezial plates 1a. First, an adhesive and/or sealant, for example a synthetic adhesive, is applied on the butt joints between plates 1a and on the edges of the central part 6 if there is one. Then, it is possible to add woven or non-woven glass fiber or a synthetic or plastic mesh on said adhesive/sealant, and finally, the glass fiber or mesh is covered again with another layer of adhesive and/ or sealant, where a different or the same adhesive/sealant can be used. The use of the glass fiber or mesh in the butt joints strengthens said attachment.
In the preferred embodiment of the invention, the components of the mounting frame 1 are made of metal, preferably aluminum or steel, although other materials such as plastic, wood, natural material, synthetic material, and/or a combination thereof, are not ruled out.
In another embodiment of the invention, in which the opening 18 created in the area of attachment of the narrowest areas of the trapezial plates 1a once mounted on the mounting frame 100 of the invention is smaller than the diameter of the valve of the drain system to be coupled in the final location of the shower tray 200, after the overturning step an additional central part 6', such as that shown in Figure 9, is placed such that it covers part of the narrowest ends converging at the lowest point of the top slab 1, fixing it and sealing it to the inner face 11 of the top slab 1 in said position. This additional central part 6', being made from the same material as the central part 6 described above, differs from same in that it only comprises a base 6a, i.e., it does not comprise the central hole or the central depression of the previous embodiment of the central part 6, but it provides in the same way additional reinforcement to the most delicate area of the shower tray 200, i.e., the area close to the drain point, and therefore provides great structural stability, while at the same time assuring the enclosing and sealing of the lowest part of the shower tray 200.
To secure the overturning step in this embodiment, only a plurality of positioning bars 10, such as those described above, will be used, and it is not necessary to use a securing bar 8, such that two consecutive stops 10' of one and the same bar 10 are arranged on each side of the butt joint between two adjacent trapezial plates 1a, as can be seen in Figure 8; the closer to the corresponding joint the better. In this case, instead of a securing bar 8 an additional positioning bar 10" could be placed, being arranged facing the bottom support 5. Said additional positioning bar 10", similar to the positioning bars 10 described above, can be extendable so as to be adjusted to the measurements of the perimeter frame 3, and comprises stops 10' which are also movable and height-adjustable but arranged only on the top face 12 of the top slab 1.
At the end of the second step according to this embodiment of the invention, it is advisable to make a hole 17 in the area where the trapezial plates 1a converge at the lowest point of the shower tray 200 to enable the connection with the drain system of the final location of the shower tray 200, as can be seen in Figure 10, such that a hole 17 going through the trapezial plates 1a, the additional central part 6', and the inner body 2 is created.
At the end of the first step of the manufacturing process of the invention, the mounting frame 100 is disassembled so as to continue with the second step, although it would not be necessary to disassemble the mounting frame 100 so as to proceed with the second step. Nevertheless, before disassembled the mounting frame 100 of the invention, it is necessary to make sure that the adhesive and/or sealant applied on the joints or edges to be attached has hardened and/or cured.
At the beginning of the second step, a framework, not shown in the drawings, is placed on the periphery of the bottom face 11 of the top slab 1 according to any of the described embodiments, and then the material 15 which will give rise to the inner body 2 of the shower tray once it is set or cured is poured. The material 15 used in the invention is a resin or an agglomerate of natural, synthetic, or chemical aggregates mixed with natural, synthetic, or chemical binders.
Optionally, before pouring the material 15 which will give rise to the inner body 2 of the shower tray 200, decorative strips not shown in the drawings could be placed on the inner perimeter of the casing, said strips preferably being of the same material as the top slab 1, improving the finish or appearance of the inner body 2.
Optionally, the inner body 2 may comprise a reinforcement mesh 7 embedded in its interior. To that end, said mesh 7 can be placed on the bottom face 12 of the top slab 1 before pouring the material 15. Thus, said mesh 7 may comprise a hole to allow the placement of the drain system of the space. Said hole can be housed in the central depression 6b of the central part 6 if the shower tray 200 comprises said central part 6.
Like the central part 6, the mesh 7 provides additional reinforcement to the area close to the drain point, which is obviously the most delicate area of the shower tray 200, so this area can be doubly reinforced, providing great structural stability.
Before pouring the material 15, the mesh 7 may or may not be adhered to the bottom face 12 of the top slab 1. If it is to be adhered to the top slab 1, the mesh 7 can be placed before disassembling the top slab 1 from the mounting frame 100.
In the preferred embodiment of the invention, the mesh 7 is made of metal, although it could also be made of plastic.
The formwork is dismantled at the end of the second step, once the material 15 forming the inner body 2 of the shower tray 200 is set or cured, the shower tray 200 being ready for use.
Optionally, it is possible to apply on the top face 12 of the top slab 1, i.e., on the usable surface of the shower tray 200, an anti-slip treatment at the end of the second step.

Claims

Mounting frame of shower trays (200) of the type comprising a top slab (1) formed from at least four trapezial plates (1a) and an inner body (2) adhered to the top slab (1a), said mounting frame (100) comprising a perimeter frame (3) formed by two longitudinal bars (3a) and two transverse bars (3b), characterized in that both the longitudinal bars (3a) and the transverse bars (3b) each comprise at least one channeled segment (4), which allows completely or partially housing an end of a corresponding trapezial plate (1a) of the top slab (1), preferably the widest end, and in that the mounting frame (100) also comprises a bottom support (5) arranged at a lower level of the perimeter frame (3), such that the trapezial plates (1a) converge in said bottom support (5), thus defining a camber of the shower tray (200) and the final shape of the shower tray (200).
Mounting frame according to claim 1, wherein the transverse bars (3b) are slidable along the longitudinal bars (3a), where they can be locked at any point of the longitudinal bars (3a).
Mounting frame according to claim 2, wherein each transverse bar (3b) comprises at each of its ends an anchoring part (13) cooperating with a corresponding longitudinal bar (3a) so as to lock the position of said transverse bar (3b).
Mounting frame according to claim 3, wherein the transverse bars (3b) are extendable.
Mounting frame according to any of the preceding claims, wherein the longitudinal bars (3a) and the transverse bars (3b) each comprise two profiles, with the corresponding channel (4) being formed upon attaching said profiles to one another, such that the width of the channel (4) of each bar (3a, 3b) is adjustable.
Mounting frame according to any of the preceding claims, wherein the bottom support (5) is removable and/or slidable with respect to the perimeter frame (3), where it can be locked at any point with respect to the perimeter frame (3).
Mounting frame according to any of the preceding claims, wherein the bottom support (5) is height-adjustable with respect to the perimeter frame (3).
Mounting frame according to any of the preceding claims, wherein the bottom support (5) comprises a housing (5") suitable for housing a central part (6) of the shower tray (200) on which the trapezial plates (1a) mounted in the frame (100) will converge.
Mounting frame according to any of the preceding claims, also comprising a securing bar (8) arranged between two parallel bars (3a, 3b) of the perimeter frame (3), preferably the longitudinal bars (3a), in a removable and/or slidable manner, said securing bar (8) comprising a top retaining element (9), being preferably height-adjustable, which is suitable for being supported simultaneously on the narrowest ends of the trapezial plates (1a), and a bottom retaining element (9') suitable for securing the narrowest ends of the trapezial plates (1a) by the bottom portion of the top slab (1) such that the narrowest ends of the trapezial plates (1a) are retained by the top retaining element (9) and the bottom retaining element (9'), and the ends opposite the narrowest ends of the trapezial plates (1a) are retained by the perimeter frame (3), thus allowing the manipulation of the assembly mounted on the mounting frame (100).
Mounting frame according to claim 8, wherein the securing bar (8) is extendable.
Mounting frame according to any of the preceding claims, also comprising at least one positioning bar (10) arranged between two parallel bars (3a, 3b) of the perimeter frame (3), preferably the longitudinal bars (3a), in a removable and/or slidable manner, said positioning bar (10) comprising a plurality of stops (10'), being preferably height-adjustable, which are suitable for being supported on the bottom face (11) and the top face (12) of the top slab (1) such that they can keep the assembly mounted in the mounting frame (100) aligned.
Mounting frame according to claim 11, wherein each stop (10') is movable on the positioning bar (10).
Mounting frame according to claim 11 or 12, wherein the positioning bar (9) is arranged on the side where the distance, in the longitudinal direction of the mounting frame (100), between the position of the bottom support (5) and an end of the perimeter frame (3) is greater.
Mounting frame according to claim 11 or 12, comprising a plurality of positioning bars (10), said bars (10) being distributed on both sides of the position of the bottom support (5).
Mounting frame according to any of claims 11 to 14, wherein each positioning bar (10) is extendable.
Mounting frame according to any of claims 11 to 15, optionally comprising an additional positioning bar (10"), being preferably extendable, which is arranged facing the bottom support (5), said additional positioning bar (10") comprising a plurality of stops (10') arranged on the top face (12) of the top slab (1), said stops (10') being preferably movable and height adjustable.
Mounting frame according to any of the preceding claims, wherein the channels (4) of the bars (3a, 3b) of the perimeter frame (3) comprise in their interior a lining, such as a flexible padded surface for example.
Method of manufacturing a prefabricated shower tray, said shower tray (200) comprising a top slab (1) and an inner body (2) adhered to the top slab (1), and the method comprising a first step in which the top slab (1) is obtained and a second step in which the inner body (2) is obtained, characterized in that the top slab (1) is formed from at least four trapezial plates (1a), such that in the first step said trapezial plates (1a) are arranged on a mounting frame (100) comprising a perimeter frame (3) completely or partially housing one of the ends of each trapezial plate (1a), preferably the widest end, such that there is obtained the final shape of the shower tray (200) and a bottom support (5) arranged at a lower level of the perimeter frame (3) such that the trapezial plates (1a) converge in said bottom support (5), thus defining a camber of the shower tray (200), and in that the method also comprises an overturning step which is carried out during the first step so as to have access to a bottom face (11) of the top slab (1), applying the adhesive and/or sealant for attaching and tightly sealing the trapezial plates (1a) to one another, both by the top face (12) and by the bottom face (11) of the top slab (1), with these being mounted on the mounting frame (100).
Method of manufacturing a shower tray according to claim 18, wherein the perimeter frame (3) comprises two longitudinal bars (3a) and two transverse bars (3b), each longitudinal and transverse bar (3a, 3b) comprising at least one channeled segment (4) which allows completely or partially housing the corresponding trapezial plates (1a) in the first step, said channels (4) preferably comprising a lining such as a flexible padded surface for example.
Method of manufacturing a shower tray according to claim 19, wherein the longitudinal bars (3a) and the transverse bars (3b) each comprise two profiles, with the corresponding channel (4) being formed upon attaching said profiles to one another, such that the width of each channel (4) is adjustable, the width of each channel (4) being adjusted at the beginning of the first step to the thickness of the corresponding trapezial plate (1a) to be housed in said channel (4).
Method of manufacturing a shower tray according to claim 19 or 20, wherein the transverse bars (3b) are slidable along the longitudinal bars (3a), where they can be locked at any point of the longitudinal bars (3a), said transverse bars (3b) preferably also being extendable, such that at the beginning of the first step, while the trapezial plates (1a) are placed in the mounting frame (100), the dimensions of the perimeter frame (3) are dynamically adjusted to the dimensions of the final shape of the shower tray (200), applying adhesive and/or sealant on the edges of the butt joints of the trapezial plates (1a) before locking the perimeter frame (3) of the mounting frame (100).
Method of manufacturing a shower tray according to any of claims 18 to 21, wherein the bottom support (5) is removable and/or slidable in the longitudinal and transverse direction of the perimeter frame (3) and height-adjustable with respect to the perimeter frame (3), where it can be locked at any point with respect to the perimeter frame (3), such that at the beginning of the first step, before starting to place the trapezial plates (1a), the position and height of the bottom support (5) are adjusted.
Method of manufacturing a shower tray according to any of claims 18 to 22, wherein the bottom support (5) comprises a housing (5") which can house a central part (6) of the shower tray (200), the trapezial plates (1a) mounted in the mounting frame (100) converging in this case on said central part (6), said central part (6) being placed on the bottom support (5), preferably before placing the trapezial plates (1a) in the mounting frame (100), said central part (6) being suitable for cooperating with the drain system of the space where the shower tray (200) is going to be placed.
Method of manufacturing a shower tray according to claim 23, wherein the central part (6) comprises a base (6a), preferably rectangular shaped, on which the narrowest ends of the trapezial plates (1a) are supported, attaching and tightly sealing said ends of the trapezial plates (1a) to said base (6a) in the first step.
Method of manufacturing a shower tray according to any of claims 18 to 24, wherein before the overturning step, a securing bar (8) is placed on the perimeter frame (3) in a removable and/or slidable manner, said bar preferably being extendable, such that a top retaining element (9) comprised in the securing bar (8), being preferably height-adjustable, is supported simultaneously on the narrowest ends of the trapezial plates (1a), and a bottom retaining element (9'), also comprised in the securing bar (8), secures the bottom portion of the narrowest ends of the trapezial plates (1a), with the narrowest ends of the trapezial plates (1a) being retained by the top retaining element (9) and the bottom retaining element (9') such that the trapezial plates (1a) are secured through the securing bar (8) and the perimeter frame (3), such that the assembly mounted on the mounting frame (100) can be turned over during the overturning step so as to allow work to continue on the bottom face (11) of the top slab (1).
Method of manufacturing a shower tray according to any of claims 18 to 25, wherein before the overturning step, a plurality of positioning bars (10) can optionally be placed, these preferably being extendable, on the perimeter frame (3), each bar (10) comprising a plurality of stops (10'), being preferably height-adjustable, arranged on the bottom face (11) and the top face (12) of the top slab (1) such that they are supported on both faces of the trapezial plates (1a), such that the positioning bars (9) keep the assembly mounted in the mounting frame (100) aligned during at least the overturning step.
Method of manufacturing a shower tray according to claim 26, wherein each stop (10') is movable on the corresponding positioning bar (10) such that two consecutive stops (10') of the corresponding positioning bar (10) are arranged on each side of the butt joint formed between two adjacent trapezial plates (1a).
Method of manufacturing a shower tray according to claim 26 or 27, wherein the positioning bars (10) are distributed on both sides of the bottom support (5).
Method of manufacturing a shower tray according to any of claims 18 to 28, wherein after the overturning step, during the first step, a layer of adhesive and/or sealant is applied on the butt joints between trapezial plates (1a), where a second layer of adhesive and/or sealant can preferably be applied on the butt joints between trapezial plates (1a), sandwiching a reinforcement between both layers, such as woven or non-woven glass fiber or a synthetic or plastic mesh.
Method of manufacturing a shower tray according to claims 23 or 24, wherein after the overturning step, during the first step, a layer of adhesive and/or sealant is applied on the edges of the central part (6).
Method of manufacturing a shower tray according to any of claims 18 to 22, wherein after the overturning step, an additional central part (6') is arranged on the inner face (11) of the top slab (1) such that it covers part of the narrowest ends converging at the lowest point of the top slab (1), fixing it and/or sealing it to the inner face (11) of the top slab (1) in said position, the additional central part (6') comprising a base (6a), preferably rectangular shaped, said additional central part (6') being suitable for cooperating with the drain system of the space where the shower tray (200) is going to be placed.
Method of manufacturing a shower tray according to claim 31, wherein before the overturning step, a plurality of positioning bars (10), being preferably extendable, is placed on the perimeter frame (3) distributed on both sides of the bottom support (5), each positioning bar (10) comprising a plurality of stops (10'), being preferably height-adjustable, arranged on the bottom face (11) and the top face (12) of the top slab (1) such that they are supported on both faces of the trapezial plates (1a), such that the positioning bars (10) keep the assembly mounted in the mounting frame (100) aligned during at least the overturning step.
Method of manufacturing a shower tray according to claim 32, wherein each stop (10') is movable on the corresponding positioning bar (10) such that two consecutive stops (10') of the corresponding positioning bar (10) are arranged on each side of the butt joint formed between two adjacent trapezial plates (1a).
Method of manufacturing a shower tray according to claim 32 or 33, wherein an additional positioning bar (10") is optionally arranged facing the bottom support (5), said additional positioning bar (10"), which is preferably extendable, comprising a plurality of stops (10') arranged on the top face (12) of the top slab (1), said stops (10') being preferably movable and height-adjustable.
Method of manufacturing a shower tray according to any of claims 31 to 34, wherein after the second step, a hole (17) is drilled in the area where the trapezial plates (1a) converge at the lowest point of the shower tray (200), going through both the trapezial plates (1a) and the additional central part (6') and the inner body (2), the additional central part (6') cooperating with the drain system of the space where the shower tray (200) is going to be placed through said hole (17).
Method of manufacturing a shower tray according to any of claims 31 to 35, wherein after the overturning step, during the first step, a layer of adhesive and/or sealant is applied on the butt joints between trapezial plates (1a) and on the edges of the additional central part (6'), where a second layer of adhesive and/or sealant can preferably be applied on the butt joints between trapezial plates (1a), sandwiching a reinforcement between both layers, such as woven or non-woven glass fiber or a synthetic or plastic mesh.
Method of manufacturing a shower tray according to any of claims 18 to 36, wherein at the beginning of the second step, the mounting frame (100) is disassembled and a formwork is placed on the periphery of the bottom face (11) of the top slab (1), and then the material (15) is poured, which material is preferably a resin or an agglomerate of natural, synthetic, or chemical aggregates mixed with natural, synthetic, or chemical binders, which will give rise to the inner body (2) of the shower tray (100) of the second step.
Method of manufacturing a shower tray according to claim 37, wherein before pouring the material (15) that will form the inner body (2), a reinforcement mesh (7), preferably being metallic or plastic, can be placed on the bottom face (11) of the top slab (1), where said mesh (7) may or may not be adhered to the inner surface (11) of the top slab (1).
Method of manufacturing a shower tray according to claim 37 or 38, wherein before pouring the material (15) which will form the inner body (2), decorative strips can be placed on the inner perimeter of the framework, these strips preferably being made from the same material as the top slab (1).
Method of manufacturing a shower tray according to any of claims 37 to 39, wherein after the setting or curing of the material (15) forming the inner body (2), the formwork is dismantled.
Method of manufacturing a shower tray according to any of claims 18 to 40, wherein an anti-slip treatment can optionally be applied on the top face (12) of the top slab (1) at the end of the second step.
Prefabricated shower tray comprising a top slab (1) and an inner body (2) adhered to the bottom face of the top slab (1), characterized in that the top slab (1) is formed from the attachment and tight sealing of at least four trapezial plates (1a), and in that the shower tray (200) also comprises a central part (6; 6') arranged between the top slab (1) and the inner body (2), such that the narrowest end of each trapezial plate (1a) of the top slab (1) converges in said central part (6; 6') at the lowest part of the top slab (1), a camber of the shower tray (200) thus being defined, said central part (6; 6') being suitable for cooperating with the drain system of the space where the shower tray (200) is going to be placed.
Prefabricated shower tray according to claim 42, wherein each trapezial plate (1a) of the top slab (1) is formed from a plurality of floor tiles.
Prefabricated shower tray according to claim 42, wherein each trapezial plate (1a) comprises a sheet of ceramic material, sintered ceramic material, resin, acrylic, natural stone, or synthetic stone.
Prefabricated shower tray according to any of claims 42 to 44, wherein the inner body (2) is made up of a material (15) such as a resin or an agglomerate of natural, synthetic, or chemical aggregates mixed with natural, synthetic, or chemical binders, preferably being reinforced with a metal or plastic mesh (7) which is embedded in the inner body (2).
Prefabricated shower tray according to claim 44, wherein the inner body (2) comprises decorative strips on the periphery covering the entire outer contour of the inner body (2), said decorative strips being made from the same material as the trapezial plates (1a).