EP3986221A2 - Waterproof or splash-resistant article - Google Patents

Waterproof or splash-resistant article

Info

Publication number
EP3986221A2
EP3986221A2 EP20723496.4A EP20723496A EP3986221A2 EP 3986221 A2 EP3986221 A2 EP 3986221A2 EP 20723496 A EP20723496 A EP 20723496A EP 3986221 A2 EP3986221 A2 EP 3986221A2
Authority
EP
European Patent Office
Prior art keywords
formed core
shell
splash
waterproof
article
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20723496.4A
Other languages
German (de)
French (fr)
Inventor
John Nichols
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kohler Mira Ltd
Original Assignee
Kohler Mira Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kohler Mira Ltd filed Critical Kohler Mira Ltd
Publication of EP3986221A2 publication Critical patent/EP3986221A2/en
Pending legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K3/00—Baths; Douches; Appurtenances therefor
    • A47K3/28—Showers or bathing douches
    • A47K3/40—Pans or trays

Definitions

  • the present disclosure relates to waterproof or splash-resistant articles.
  • the waterproof or splash-resistant articles may be intended for use indoors or outdoors, typically in a domestic or commercial setting, e.g. in kitchens, wet rooms, shower rooms or bathrooms.
  • the waterproof or splash-resistant articles may include articles of sanitary ware, in particular, but not exclusively, shower trays.
  • the disclosure also relates to methods of manufacture of such waterproof or splash-resistant articles.
  • Articles of sanitary ware can include, for example, baths, sinks, toilets, shower trays, waterproof or splash-resistant panels for covering surfaces such as walls, floors or ceilings, shower panels, shower columns or the like.
  • any shower tray it is important that the shower tray can withstand impacts, mechanical stresses and strains during installation and use.
  • FIG. 1 Show trays comprising an acrylic-capped acrylonitrile butadiene styrene (ABS) upper layer supported by a resin-stone base are known.
  • Such trays are usually manufactured by pouring a resin-stone filler into a mould containing a shell of acrylic- capped ABS pre-formed to the desired shape of the top and sides of the shower tray and hardening the filler to form the base.
  • the acrylic-capped ABS upper layer forms the outer surface of the exposed parts of the tray in its installed position and the filler supports the upper layer and forms an underside of the tray that contacts the surface on which the tray is installed.
  • shower trays comprising a plastic cap or shell filled with a stone-resin material are sometimes called polymer-concrete shower trays.
  • W02005/011455 discloses shower trays and like articles, in which an outer shell of plastics material encases a core of stone-resin material.
  • a problem with polymer-concrete shower trays is that the weight of the trays can make lifting and carrying the trays during transport and installation difficult. Lifting and carrying heavy trays can result in injury to the lifter(s) and/or cause the lifter(s) to drop the tray resulting in damage to the tray.
  • 800 mm by 800 mm trays can weigh from around 26 kg to 33 kg. Hence, more than one person may be required to lift and handle safely a typical polymer-concrete shower tray.
  • shower tray comprises a plastic shell encompassing a polyurethane (PU) foam core.
  • PU polyurethane
  • a problem with polymer-concrete shower trays and shower trays with PU foam cores is that both types of shower tray can be difficult to recycle. Further, the manufacture of both of these types of shower tray typically includes the use of petroleum-based ingredients, which may be undesirable on environmental grounds.
  • a first aspect provides a waterproof or splash-resistant article comprising a shell defining at least partially an internal volume, the internal volume having a shape; and a pre-formed core, wherein the pre-formed core has substantially the shape of the internal volume and the pre-formed core occupies 90% or more of the internal volume.
  • manufacture of the article may be simplified. Also, in contrast to forming a core in situ, e.g. by curing, there may be less likelihood of the article being distorted.
  • the pre-formed core may occupy 95% or more, 97% or more or 98% or more of the internal volume.
  • the pre-formed core may occupy substantially all of the internal volume.
  • the shape of the pre-formed core may reflect a shape of the waterproof or splash- resistant article.
  • the shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
  • the pre-formed core may comprise a plurality of pre-formed core sections. In embodiments comprising a plurality of pre-formed core sections, the pre-formed core sections may be joined together to provide the pre-formed core.
  • the pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding.
  • the pre-formed core sections may be bonded together using an adhesive.
  • the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core.
  • the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
  • the pre-formed core may comprise a unitary body.
  • the pre-formed core or pre-formed core sections may comprise, or consist essentially of, a composite comprising a mix of two or more materials.
  • the composite may comprise one or more filler materials mixed with a binder, e.g. a resin binder.
  • the binder may comprise an adhesive.
  • the filler material(s) may comprise a wood-based material.
  • the filler materials may comprise one or more of: wood, sawdust, wood chippings, wood shavings, rubber (e.g. rubber crumb), cork and a plastics material (e.g. a polymeric material).
  • One or more of the filler materials may comprise recycled material.
  • the pre-formed core or pre-formed core sections may comprise used sawdust and/or wood chippings and/or wood shavings.
  • the pre-formed core or pre-formed core sections may comprise rubber crumb, e.g. recycled from used car tyres.
  • surplus, defective, unused, damaged, waste or end-of-life pre-formed cores may be broken up, e.g. crushed, and incorporated back into the filler material for further pre-formed cores. This could reduce waste, volume of raw materials used, energy expenditure during manufacture and/or cost of the end product (i.e. the waterproof or splash-resistant article).
  • the pre-formed core or the pre-formed core sections may include a foam or honeycomb structure.
  • the pre-formed core or the pre-formed core sections may be formed by a moulding process such as a compression moulding process.
  • the pre-formed core or the pre formed core sections may be formed by injection moulding, casting, machining or the like.
  • the waterproof or splash-resistant article may be relatively light, whilst having the mechanical properties required for its intended use.
  • a shower tray comprising such a pre-formed core may be considerably lighter than an equivalent polymer-concrete shower tray.
  • a shower tray may be more easily handled than known polymer-concrete shower trays and may even be light enough to be lifted safely by one person.
  • Another benefit of producing a relatively light waterproof or splash-resistant article is that the article may require less packaging, since there may be a reduced risk of sustaining damage particularly during transport and installation.
  • the shell may comprise, or consist essentially of, a plastics material.
  • the plastics material may include an acrylic.
  • the waterproof or splash-resistant article may be broken up, e.g. crushed, and incorporated back into the filler material for further pre-formed cores. This could prevent end-of-life articles from being sent to landfill.
  • the shell may extend at least partially around the pre-formed core.
  • the shell may encompass 50% or more of the pre-formed core.
  • the shell may encompass the pre formed core.
  • the shell may be substantially watertight. A portion of the pre-formed core may not be covered by the shell.
  • the shell may comprise one or more shell members.
  • the shell may comprise a plurality of shell members.
  • the shell member(s) may be pre-formed.
  • the shell or one or more of the shell member(s) may be formed directly on to the pre-formed core.
  • the shell or one or more of the shell member(s) may be made at least partially by any suitable moulding or forming process, e.g. vacuum forming.
  • the shell or one or more of the shell member(s) may be made at least partially by gel coating.
  • Gel coating may include application of a gel on to at least a portion of the pre-formed core and/or on to at least a portion of the shell or one or more of the shell member(s) by means of spraying, pouring or any other suitable method.
  • a first shell member may be configured to cover at least partially or entirely a first surface of the pre-formed core.
  • the first shell member may be adapted to provide, in use, a fluid-contacting surface, e.g. a water-contacting surface.
  • the article may comprise a shower tray and the first shell member may provide a water collection surface and a floor.
  • the floor may be provided with one or more anti-slip features such as protrusions, ridges or roughened regions.
  • the shell may further comprise one or more further shell members, e.g. a second shell member.
  • the first shell member and one or more further shell members, e.g. the second shell member may together encompass the entire pre-formed core.
  • the first shell member and one or more further shell members, e.g. the second shell member may be joined together with a substantially water-tight seal.
  • the shell or a portion thereof may comprise one or more indicia, e.g. to indicate a brand name, to provide installation or safety instructions or to provide some surface decoration.
  • the shell or shell members may be of uniform thickness.
  • the shell or shell members may have a thickness of less than 0.2 mm, or less than 0.5mm, 1mm, 2mm, 3mm, 5 mm, or a thickness of 5mm or greater.
  • the shell or shell members may comprise regions of non-uniform thickness.
  • the regions of non-uniform thickness may comprise anti-slip features, or may comprise weight saving features.
  • the shell or the shell members may comprise a softer material disposed in one or more regions underneath an outer shell material (e.g. a hard plastics material such as an acrylic), to provide impact absorption, in use.
  • the softer material may comprise a plastics material such as acrylonitrile butadiene styrene (ABS).
  • ABS acrylonitrile butadiene styrene
  • the ratio of the thickness of the softer material (e.g. ABS) to the outer shell material (e.g. acrylic) may be at least 5: 1 and/or up to 15: 1. For instance, the ratio of the thickness of the ABS to acrylic may be 9: 1.
  • a portion of the shell may be 2 mm thick with a skin of acrylic 0.2 mm thick and a sub-layer of ABS 1.8 mm thick. Such a portion of the shell may provide a floor for a shower tray.
  • At least a portion of the shell or shell members may be coated with, or have impregnated therein, an antimicrobial agent.
  • the shell or one or more of the shell member(s) may be bonded, e.g. adhered, to the pre-formed core. Any suitable adhesive may be used to adhere the shell or one of more of the shell member(s) to the pre-formed core.
  • Heat and/or pressure may be applied to the shell or one or more of the shell member(s) during bonding to the pre-formed core.
  • a thicker layer of adhesive may be applied to one or more regions of the pre-formed core, e.g. regions adjacent joins between two shell members.
  • the thicker layer of adhesive may thus help to provide a watertight seal between shell members.
  • the article may be trimmed following the bonding, e.g. adhesion, of the shell or the shell members to the pre-formed core.
  • a thicker layer of adhesive may be applied to the pre-formed core at regions where the article is to be trimmed.
  • the thicker layer of adhesive may prevent exposure of the pre-formed core after the article has been trimmed. This may have the advantage of preventing the ingress of, for example, water, dirt, or other fluids, in use, and/or ensuring a secure bond is formed between the pre-formed core and the shell at potential regions of weakness.
  • the trimming process may leave the pre-formed core intact. This may have the advantage of not affecting the mechanical properties of the pre-formed core during post-processing.
  • the regions having thicker layers of adhesive may allow for the article of sanitary ware to be further trimmed during installation, without cutting the pre-formed core. This may have the advantage of providing an improved means of installation, which may be useful when installing the article in an area having an irregular shape and/or unusual dimensions.
  • the waterproof or splash-resistant article may comprise an article of sanitary ware or part thereof.
  • the article of sanitary ware may include, for example, a bath, a sink, a toilet, a shower tray, a waterproof or splash-resistant panel for covering a surface such as a wall, floor or ceiling, a shower panel, a shower column or the like.
  • the waterproof or splash-resistant article e.g. article of sanitary ware, may comprise a fluid, e.g. water, collection surface.
  • the fluid collection surface may be configured to slope towards a waste.
  • a second aspect provides a pre-formed core for a waterproof or splash-resistant article, wherein the pre-formed core has a shape that reflects the shape of the waterproof or splash-resistant article, and wherein the pre-formed core comprises, or consists essentially of, a composite comprising a mix of one or more filler materials and a binder, wherein the one or more filler materials comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material (e.g. a polymeric material).
  • the binder may comprise a resin binder.
  • the binder may comprise an adhesive.
  • the filler materials may comprise recycled material.
  • the pre-formed core may comprise used sawdust and/or wood chippings and/or wood shavings.
  • the pre-formed core may comprise rubber crumb, e.g. recycled from used car tyres.
  • the shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
  • the pre-formed core may comprise a plurality of pre-formed core sections.
  • the pre-formed core sections may be joined together to provide the pre-formed core.
  • the pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding.
  • the pre-formed core sections may be bonded together using an adhesive.
  • the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core.
  • the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
  • the pre-formed core may comprise a unitary body.
  • the pre-formed core or the pre-formed core sections may include a foam or a honeycomb structure.
  • the pre-formed core or the pre-formed core sections may be formed by a moulding process such as a compression moulding process.
  • the pre-formed core or the pre formed core sections may be formed by injection moulding, casting, machining or the like.
  • a third aspect provides an ablutionary or plumbing system comprising:
  • the waterproof or splash-resistant article having a fluid collection surface arranged to collect, in use, fluid emitted from the fluid delivery device.
  • the waterproof or splash-resistant article may comprise an article of sanitary ware.
  • the fluid collection surface may be configured to slope towards a waste.
  • the fluid delivery device may comprise a faucet, a tap, a sprayer or a spray head for a shower.
  • the fluid may be water.
  • a fourth aspect provides a shower and/or bath system comprising one or more waterproof or splash-resistant articles according to the first aspect.
  • the shower and/or bath system may comprise at least one fluid delivery device.
  • the fluid delivery device may comprise a faucet, a tap, a sprayer or a spray head for a shower.
  • the fluid may be water.
  • a fifth aspect provides a method of manufacture of a waterproof or splash-resistant article, e.g. a waterproof or splash-resistant article according to the first aspect, comprising:
  • manufacture of the article may be simplified. Also, in contrast to forming a core in situ, e.g. by curing, there may be less likelihood of the article being distorted.
  • the shell may define at least partially an internal volume, the internal volume having a shape and the pre-formed core may have substantially the shape of the internal volume and may occupy 90% or more of the internal volume.
  • the pre-formed core may occupy 95% or more, 97% or more or 98% or more of the internal volume.
  • the pre-formed core may occupy substantially all of the internal volume.
  • the shape of the pre-formed core may reflect a shape of the waterproof or splash- resistant article.
  • the shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
  • the method may comprise the preliminary step or steps of forming the pre-formed core and/or one or more of the pre-formed shell members.
  • the pre-formed core may comprise a plurality of pre-formed core sections.
  • the pre-formed core sections may be joined together to provide the pre-formed core.
  • the pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding.
  • the pre-formed core sections may be bonded together using an adhesive.
  • the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core.
  • the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
  • the pre-formed core may comprise a unitary body.
  • the pre-formed core or pre-formed core sections may comprise, or consist essentially of, a composite comprising a mix of two or more materials.
  • the composite may comprise one or more filler materials mixed with a binder, e.g. a resin binder.
  • the binder may comprise an adhesive.
  • the filler material(s) may comprise a wood-based material.
  • the filler materials may comprise one or more of: wood, sawdust, wood chippings, wood shavings, rubber (e.g. rubber crumb), cork and a plastics material (e.g. a polymeric material).
  • One or more of the filler materials may comprise recycled material.
  • the pre-formed core or pre-formed core sections may comprise used sawdust and/or wood chippings and/or wood shavings.
  • the pre-formed core or pre-formed core sections may comprise rubber crumb, e.g. recycled from used car tyres.
  • the pre-formed core or the pre-formed core sections may include a foam or honeycomb structure.
  • the pre-formed core or the pre-formed core sections may be formed by a moulding process such as a compression moulding process.
  • the pre-formed core or the pre-formed core sections may be formed by injection moulding, casting, machining or the like.
  • the waterproof or splash-resistant article may be relatively light, whilst having the mechanical properties required for its intended use.
  • a shower tray comprising such a pre-formed core may be considerably lighter than an equivalent polymer-concrete shower tray.
  • a shower tray may be more easily handled than known polymer-concrete shower trays and may even be light enough to be lifted safely by one person.
  • Another benefit of producing a relatively light waterproof or splash-resistant article is that the article may require less packaging, since there may be a reduced risk of sustaining damage particularly during transport and installation.
  • the shell may comprise, or consist essentially of, a plastics material.
  • the plastics material may include an acrylic.
  • the shell may extend at least partially around the pre-formed core.
  • the shell may encompass 50% or more of the pre-formed core.
  • the shell may encompass the pre formed core.
  • the shell may be substantially watertight. A portion of the pre-formed core may not be covered by the shell.
  • the shell may comprise a plurality of shell members.
  • the shell or one or more of the shell member(s) may be made at least partially by any suitable moulding or forming process, e.g. vacuum forming.
  • a first shell member may be configured to cover at least partially or entirely a first surface of the pre-formed core.
  • the first shell member may be adapted to provide, in use, a fluid-contacting surface, e.g. a water-contacting surface.
  • the article may comprise a shower tray and the first shell member may provide a water collection surface and a floor.
  • the floor may be provided with one or more anti-slip features such as protrusions, ridges or roughened regions.
  • the shell may further comprise one or more further shell members, e.g. a second shell member.
  • the first shell member and one or more further shell members, e.g. the second shell member may together encompass the entire pre-formed core.
  • the first shell member and one or more further shell members, e.g. the second shell member may be joined together with a substantially water-tight seal.
  • the shell or a portion thereof may comprise one or more indicia, e.g. to indicate a brand name, to provide installation or safety instructions or to provide some surface decoration.
  • the shell or shell members may be of uniform thickness.
  • the shell or shell members may have a thickness of less than 0.2 mm, or less than 0.5mm, 1mm, 2mm, 3mm, 5 mm, or a thickness of 5mm or greater.
  • the shell or shell members may comprise regions of non-uniform thickness.
  • the regions of non-uniform thickness may comprise anti-slip features, or may comprise weight saving features.
  • the shell or the shell members may comprise a softer material disposed in one or more regions underneath an outer shell material (e.g. a hard plastics material such as an acrylic), to provide impact absorption, in use.
  • the softer material may comprise a plastics material such as acrylonitrile butadiene styrene (ABS).
  • the ratio of the thickness of the softer material (e.g. ABS) to the outer shell material (e.g. acrylic) may be at least 5: 1 and/or up to 15: 1.
  • the ratio of the thickness of the ABS to acrylic may be 9: 1.
  • a portion of the shell may be 2 mm thick with a skin of acrylic 0.2 mm thick and a sub-layer of ABS 1.8 mm thick Such a portion of the shell may provide a floor for a shower tray.
  • At least a portion of the shell or shell members may be coated with, or have impregnated therein, an antimicrobial agent.
  • Any suitable adhesive may be used to bond the shell member(s) to the pre-formed core.
  • Heat and/or pressure may be applied to the shell member(s) during bonding to the pre formed core.
  • a thicker layer of adhesive may be applied to one or more regions of the pre-formed core, e.g. regions adjacent joins between two shell members. The thicker layer of adhesive may thus help to provide a watertight seal between shell members.
  • the article may be trimmed following the bonding, e.g. adhesion, of the shell member(s) to the pre-formed core.
  • a thicker layer of adhesive may be applied to the pre-formed core at regions where the article is to be trimmed.
  • the thicker layer of adhesive may prevent exposure of the pre-formed core after the article has been trimmed. This may have the advantage of preventing the ingress of, for example, water, dirt, or other fluids, in use, and/or ensuring a secure bond is formed between the pre-formed core and the shell at potential regions of weakness.
  • the trimming process may leave the pre-formed core intact. This may have the advantage of not affecting the mechanical properties of the pre-formed core during post-processing.
  • the regions having thicker layers of adhesive may allow for the article of sanitary ware to be further trimmed during installation, without cutting the pre-formed core. This may have the advantage of providing an improved means of installation, which may be useful when installing the article in an area having an irregular shape and/or unusual dimensions.
  • the waterproof or splash-resistant article may comprise an article of sanitary ware or part thereof.
  • the article of sanitary ware may include, for example, a bath, a sink, a toilet, a shower tray, a waterproof or splash-resistant panel for covering a surface such as a wall, floor or ceiling, a shower panel, a shower column or the like.
  • the waterproof or splash-resistant article e.g. article of sanitary ware, may comprise a fluid collection surface.
  • the fluid collection surface may be configured to slope towards a waste.
  • the method may further comprise trimming the article to provide an intended shape.
  • the method may comprise applying a decorative layer or coating.
  • the method may further comprise a step of applying a coating, e.g. a gel coating, to a surface of the pre-formed core.
  • a sixth aspect provides a method of manufacture of a waterproof or splash-resistant article, e.g. a waterproof or splash-resistant article according to the first aspect, comprising:
  • forming a shell on the pre-formed core wherein at least a portion of the shell is formed by applying a coating on to a surface of the preformed core.
  • the shell may define at least partially an internal volume, the internal volume having a shape and the pre-formed core may have substantially the shape of the internal volume and may occupy 90% or more of the internal volume.
  • the shell may be formed at least partially by gel coating.
  • Gel coating may include application of a gel on to at least a portion of the pre-formed core and/or on to at least a portion of the shell or one or more of the shell member(s) by means of spraying, pouring or any other suitable method.
  • a seventh aspect provides a method of manufacture of a pre-formed core for a waterproof or splash-resistant article, e.g. a pre-formed core according to the second aspect, the pre-formed core having a shape that reflects the shape of the waterproof or splash-resistant article, comprising:
  • the one or more filler materials comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material;
  • the pre-formed core may be formed by a moulding process such as a compression moulding process.
  • the pre-formed core or the pre-formed core sections may be formed by injection moulding, casting, machining or the like.
  • the binder may comprise a resin binder.
  • the binder may comprise an adhesive.
  • One or more of the filler materials may comprise recycled material.
  • the pre-formed core may comprise used sawdust and/or wood chippings and/or wood shavings.
  • the pre-formed core may comprise rubber crumb, e.g. recycled from used car tyres.
  • the shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
  • the pre-formed core may comprise a plurality of pre-formed core sections.
  • the pre-formed core sections may be joined together to provide the pre-formed core.
  • the pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding.
  • the pre-formed core sections may be bonded together using an adhesive.
  • the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core.
  • the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
  • the pre-formed core may comprise a unitary body.
  • the pre-formed core or the pre-formed core sections may include a foam or a honeycomb structure.
  • Figure 1 is an exploded view of an example shower tray
  • Figure 2 is a cross-sectional view through the pre-formed components of the shower tray of Figure 1;
  • Figure 3a is a cross-sectional view through a region near the waste of the example shower tray prior to any trimming process
  • Figure 3b is a cross-sectional view through the region near the waste of the shower tray as illustrated in Figure 3b after a trimming process
  • Figure 4a is a cross-sectional view through an edge region of the example shower tray prior to any trimming process
  • Figure 4b is a cross-sectional view through the edge region of the example shower tray as illustrated in Figure 4a after a trimming process;
  • Figure 5 is a cross-sectional view of a pre-formed core for a bath.
  • Figure 7 is a flow chart of an example embodiment of a method of manufacture of an article of sanitary ware.
  • FIG 1 is an exploded view of a shower tray 1 .
  • the shower tray l is a square shower tray. It will be appreciated, however, that the shower tray 1 may have any other general form, e.g. a rectangular or non-rectangular shape .
  • the shower tray 1 comprises a floor 2 and inner walls 3 defining a well for collecting water dispensed from a shower head (not shown) and confining the collected water to the shower tray 1 .
  • the floor 2 may be provided with an anti-slip surface (not shown), which may for example comprise a plurality of raised ribs arranged in any suitable pattern.
  • a hole 4 is provided at an edge of the floor 2 for a waste pipe (not shown) .
  • the hole 4 may be located at any location within the floor 2.
  • the floor 2 has a slope with a gradient of at least 1 ° towards the hole 4 so that water in the shower tray 1 will self-drain towards the hole 4.
  • the inner walls 3 lead to an outwardly extending upper surface 27 at the top of the shower tray 1 , thereby forming a rim 30 that extends around the floor 2 on all four sides.
  • the outwardly extending upper wall 27 may be substantially horizontal.
  • the outwardly extending upper wall may lead to an upstand (not shown) at the outer peripheral edge of the shower tray 1.
  • the shower tray 1 has a pattern of strengthening ribs 32 on an intended underside thereof.
  • Outer walls 5 extend downwardly from an outer edge of the rim 30 to a skirt 34.
  • the skirt 34 extends around the periphery of the shower tray 1.
  • the skirt 34 may be removed in a trimming step during manufacture of the shower tray 1.
  • the shower tray 1 comprises a shell 9 and a pre-formed core 10.
  • the shell 9 encompasses the pre-formed core 10.
  • the shell 9 comprises a first shell member 6 and a second shell member 8.
  • the first shell member 6 constitutes an upper shell member.
  • the second shell member 8 constitutes a lower shell member.
  • the first shell member 6 and/or the second shell member 8 may be vacuum formed.
  • the shell 9 formed by the first shell member 6 and the second shell member 8 has an internal volume.
  • the pre-formed core 10 has substantially the same shape as the shower tray 1.
  • the pre-formed core 10 occupies more than 95% of the internal volume defined by the shell 9.
  • the pre-formed core 10 provides the shower tray 1 with structural integrity.
  • the pre-formed core 10 comprises a single body.
  • the pre-formed core is made of a composite comprising one or more filler materials mixed with a binder.
  • the filler material(s) may comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material.
  • the binder may comprise an adhesive.
  • the pre-formed core 10 may comprise, or consist essentially of, a composite made up of a wood-based filler material such as sawdust, wood chippings and/or wood shavings and an adhesive binder.
  • the pre-formed core may be formed by a compression moulding process.
  • the pre-formed core 10 may be formed of a plurality of pre-formed core sections. The pre-formed core sections may be joined together and/or may be configured to interlock with each other.
  • the first shell member 6 provides an upper surface of the shower tray 1.
  • the upper surface of the shower tray 1 includes a water collection surface including the floor 2.
  • the second shell member 8 provides a lower surface of the shower tray 1.
  • the lower surface of the shower tray 1 includes the pattern of strengthening ribs 32.
  • the lower surface of the shower tray is provided with a plurality of attachment points 36 for the attachment of feet (not shown).
  • the pre-formed core 10 is adhered to the first shell member 6 and the second shell member 8. Heat and/or pressure may be applied to the shell or the shell members during adhesion of the shell or the shell members to the pre-formed core.
  • the pre-formed first shell member 6 is held upside down.
  • An adhesive is applied to an inner surface of the first shell member 6, e.g. by spraying.
  • the pre-formed core 10 is then placed within the first shell member 6.
  • the pre formed second shell member 8, with adhesive applied to an inner surface thereof, is then put in place over the pre-formed core 10 such that the shell 9 formed by the first shell member 6 and the second shell member 8 completely encompasses the pre formed core 10.
  • adhesive may be applied to one or more surfaces of the pre-formed core 10.
  • a thicker layer of adhesive may be applied at regions where trimming is to take place, for example in a region near the waste 4 and/or a region near the outer wall 5 and the skirt 34, as will be described with reference to Figures 3a, 3b, 4a, 4b.
  • Heat and/or pressure may be applied to promote adhesion between the first and second shell members 6, 8 and the pre-formed core 10.
  • Figures 3a and 3b show in cross-section a region near the waste 4, before ( Figure 3a) and after ( Figure 3b) trimming along a trim line indicated by a dashed line 24.
  • a layer of adhesive 20 is shown, which adheres the second core member 8 to the pre formed core 10.
  • the layer of adhesive 20 adheres the second shell member 8 to the first shell member 6.
  • a thicker layer of adhesive 22 is provided.
  • the trim line 24 is disposed a little below an underside of the second shell member 8.
  • the trim line 24 passes through a lower portion of, or just beneath, the thicker layer of adhesive 22.
  • the layer of adhesive 20 is exposed proximal the thicker layer of adhesive 22 between an edge of the first shell member 6 and an edge of the second shell member 8.
  • the thicker layer of adhesive 22 ensures that a water-tight seal protecting the pre-formed core 10 is maintained after trimming.
  • Figures 4a and 4b show in cross-section an edge region of the shower tray 1, before ( Figure 4a) and after (Figure 4b) trimming along a trim line indicated by a dashed line 44.
  • the layer of adhesive 20 is shown, which adheres the second core member 8 to the pre-formed core 10.
  • the layer of adhesive 20 adheres the second shell member 8 to the first shell member 6.
  • a thicker layer of adhesive 42 is provided in an region around a lower corner of the pre-formed core 10.
  • the trim line 44 is disposed a little below an underside of the second shell member 8.
  • the trim line 44 passes through a lower portion of, or just beneath, the thicker layer of adhesive 42.
  • the layer of adhesive 20 is exposed proximal to the thicker layer of adhesive 42 between an edge of the first shell member 6 and an edge of the second shell member 8.
  • the thicker layer of adhesive 42 ensures that a water-tight seal protecting the pre-formed core 10 is maintained after trimming.
  • Figure 5 shows in cross-section a pre-formed core 50 for a bath.
  • the pre-formed core 50 has a shape which reflects the shape of the bath.
  • the bath would comprise a shell (not shown) comprising one or more shell members.
  • the pre-formed core 50 would occupy 90% or more of an internal volume defined at least partially by the shell.
  • the pre-formed core 50 comprises a first pre-formed core section 51 and a second pre formed core section 52.
  • the first pre-formed core section 51 includes a side portion 55 and a base portion 57.
  • the second pre-formed core section 52 includes a side portion 54 and a base portion 56.
  • the second pre-formed core section 52 is a mirror image of the first pre-formed core section 51.
  • the first pre-formed core section 51 is adhered to the second pre-formed core section 52 at a join 53.
  • the join 53 extends in longitudinal direction and is located at a midpoint of the base portion of the pre-formed core 50.
  • the first and second pre-formed core sections 51, 52 are each made of a composite comprising one or more filler materials mixed with a binder.
  • the filler material(s) may comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material.
  • the binder may comprise an adhesive.
  • first and second pre-formed core sections 51, 52 may comprise, or consist essentially of, a composite made up of a wood-based filler material such as sawdust, wood chippings and/or wood shavings and an adhesive binder.
  • the first and second pre-formed core sections 51, 52 may be formed by a compression moulding process.
  • Figure 6 is a flow chart illustrating an example method of manufacture of a waterproof or splash-resistant article such as the shower tray 1.
  • a first step 601 includes providing a pre-formed core.
  • the pre-formed core may be as described herein and may have been manufactured by any suitable process, e.g. a compression moulding process.
  • the pre-formed core may comprise, or consist essentially of, a composite comprising a mix of a wood-based filler material (e.g. sawdust, wood chippings or wood shavings) and a resin binder.
  • a wood-based filler material e.g. sawdust, wood chippings or wood shavings
  • a second step 602 includes providing a shell.
  • the shell may comprise a plurality of shell members.
  • the shell or shell members may be pre-formed, e.g. by vacuum forming.
  • the shell or shell members may comprise a plastics material such as an acrylic.
  • a third step 603 includes adhering the shell or shell members to the pre-formed core.
  • Any suitable adhesive may be applied to the pre-formed core and/or the shell or shell members by any suitable means, e.g. by spraying. Heat and/or pressure may be applied to the shell or the shell members during adhesion of the shell or the shell members to the pre-formed core. A thicker layer of adhesive may be applied at regions where trimming is to take place.
  • a fourth step 604 includes trimming the shell or shell portions to provide an article having the intended shape of waterproof or splash-resistant article.
  • the method of manufacture may comprise one or more additional machining or finishing steps.
  • at least a portion of the shell may be provided by applying a coating to the pre-formed core.
  • a gel coating process may be used to apply the coating to the pre-formed core.

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  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Epidemiology (AREA)
  • General Health & Medical Sciences (AREA)
  • Laminated Bodies (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Glass Compositions (AREA)
  • Ceramic Products (AREA)

Abstract

A waterproof or splash-resistant article comprising: a shell defining at least partially an internal volume, the internal volume having a shape; and a pre-formed core, wherein the pre-formed core has substantially the shape of the internal volume and the pre-formed core occupies 90% or more of the internal volume.

Description

WATERPROOF OR SPLASH-RESISTANT ARTICLE
The present disclosure relates to waterproof or splash-resistant articles. The waterproof or splash-resistant articles may be intended for use indoors or outdoors, typically in a domestic or commercial setting, e.g. in kitchens, wet rooms, shower rooms or bathrooms. The waterproof or splash-resistant articles may include articles of sanitary ware, in particular, but not exclusively, shower trays. The disclosure also relates to methods of manufacture of such waterproof or splash-resistant articles.
Articles of sanitary ware can include, for example, baths, sinks, toilets, shower trays, waterproof or splash-resistant panels for covering surfaces such as walls, floors or ceilings, shower panels, shower columns or the like.
For any shower tray, it is important that the shower tray can withstand impacts, mechanical stresses and strains during installation and use.
Shower trays comprising an acrylic-capped acrylonitrile butadiene styrene (ABS) upper layer supported by a resin-stone base are known. Such trays are usually manufactured by pouring a resin-stone filler into a mould containing a shell of acrylic- capped ABS pre-formed to the desired shape of the top and sides of the shower tray and hardening the filler to form the base. In this way, the acrylic-capped ABS upper layer forms the outer surface of the exposed parts of the tray in its installed position and the filler supports the upper layer and forms an underside of the tray that contacts the surface on which the tray is installed.
Shower trays comprising a plastic cap or shell filled with a stone-resin material are sometimes called polymer-concrete shower trays.
An example of a polymer-concrete shower tray is disclosed in W02005/011455. W02005/011455 discloses shower trays and like articles, in which an outer shell of plastics material encases a core of stone-resin material.
A problem with polymer-concrete shower trays is that the weight of the trays can make lifting and carrying the trays during transport and installation difficult. Lifting and carrying heavy trays can result in injury to the lifter(s) and/or cause the lifter(s) to drop the tray resulting in damage to the tray. Typically, 800 mm by 800 mm trays can weigh from around 26 kg to 33 kg. Hence, more than one person may be required to lift and handle safely a typical polymer-concrete shower tray.
Another problem is that polymer-concrete shower trays can sometimes suffer distortion, due to curing of the resin during manufacture.
Another known type of shower tray comprises a plastic shell encompassing a polyurethane (PU) foam core. Such shower trays are sometimes perceived as being cheap or of inferior quality, due to their lightweight nature.
A problem with polymer-concrete shower trays and shower trays with PU foam cores is that both types of shower tray can be difficult to recycle. Further, the manufacture of both of these types of shower tray typically includes the use of petroleum-based ingredients, which may be undesirable on environmental grounds.
It would therefore be beneficial to mitigate or at least reduce one or more of the problems associated with the prior art.
A first aspect provides a waterproof or splash-resistant article comprising a shell defining at least partially an internal volume, the internal volume having a shape; and a pre-formed core, wherein the pre-formed core has substantially the shape of the internal volume and the pre-formed core occupies 90% or more of the internal volume.
By employing a pre-formed core, manufacture of the article may be simplified. Also, in contrast to forming a core in situ, e.g. by curing, there may be less likelihood of the article being distorted.
The pre-formed core may occupy 95% or more, 97% or more or 98% or more of the internal volume. The pre-formed core may occupy substantially all of the internal volume.
The shape of the pre-formed core may reflect a shape of the waterproof or splash- resistant article. The shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article. The pre-formed core may comprise a plurality of pre-formed core sections. In embodiments comprising a plurality of pre-formed core sections, the pre-formed core sections may be joined together to provide the pre-formed core. The pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding. The pre-formed core sections may be bonded together using an adhesive.
Additionally or alternatively, the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core. For instance, the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
The pre-formed core may comprise a unitary body.
The pre-formed core or pre-formed core sections may comprise, or consist essentially of, a composite comprising a mix of two or more materials.
The composite may comprise one or more filler materials mixed with a binder, e.g. a resin binder. The binder may comprise an adhesive.
The filler material(s) may comprise a wood-based material. The filler materials may comprise one or more of: wood, sawdust, wood chippings, wood shavings, rubber (e.g. rubber crumb), cork and a plastics material (e.g. a polymeric material).
One or more of the filler materials may comprise recycled material. For example, the pre-formed core or pre-formed core sections may comprise used sawdust and/or wood chippings and/or wood shavings. The pre-formed core or pre-formed core sections may comprise rubber crumb, e.g. recycled from used car tyres.
Advantageously, surplus, defective, unused, damaged, waste or end-of-life pre-formed cores may be broken up, e.g. crushed, and incorporated back into the filler material for further pre-formed cores. This could reduce waste, volume of raw materials used, energy expenditure during manufacture and/or cost of the end product (i.e. the waterproof or splash-resistant article). The pre-formed core or the pre-formed core sections may include a foam or honeycomb structure.
The pre-formed core or the pre-formed core sections may be formed by a moulding process such as a compression moulding process. The pre-formed core or the pre formed core sections may be formed by injection moulding, casting, machining or the like.
By employing a pre-formed core comprising a composite comprising a mix of two or more materials such as those mentioned above, the waterproof or splash-resistant article may be relatively light, whilst having the mechanical properties required for its intended use. For example, a shower tray comprising such a pre-formed core may be considerably lighter than an equivalent polymer-concrete shower tray. Hence, such a shower tray may be more easily handled than known polymer-concrete shower trays and may even be light enough to be lifted safely by one person.
Another benefit of producing a relatively light waterproof or splash-resistant article is that the article may require less packaging, since there may be a reduced risk of sustaining damage particularly during transport and installation.
The shell may comprise, or consist essentially of, a plastics material. The plastics material may include an acrylic.
Advantageously, the waterproof or splash-resistant article may be broken up, e.g. crushed, and incorporated back into the filler material for further pre-formed cores. This could prevent end-of-life articles from being sent to landfill.
The shell may extend at least partially around the pre-formed core. The shell may encompass 50% or more of the pre-formed core. The shell may encompass the pre formed core. The shell may be substantially watertight. A portion of the pre-formed core may not be covered by the shell.
The shell may comprise one or more shell members. The shell may comprise a plurality of shell members. The shell member(s) may be pre-formed. The shell or one or more of the shell member(s) may be formed directly on to the pre-formed core. The shell or one or more of the shell member(s) may be made at least partially by any suitable moulding or forming process, e.g. vacuum forming. The shell or one or more of the shell member(s) may be made at least partially by gel coating. Gel coating may include application of a gel on to at least a portion of the pre-formed core and/or on to at least a portion of the shell or one or more of the shell member(s) by means of spraying, pouring or any other suitable method.
A first shell member may be configured to cover at least partially or entirely a first surface of the pre-formed core. The first shell member may be adapted to provide, in use, a fluid-contacting surface, e.g. a water-contacting surface. For example, the article may comprise a shower tray and the first shell member may provide a water collection surface and a floor. The floor may be provided with one or more anti-slip features such as protrusions, ridges or roughened regions.
The shell may further comprise one or more further shell members, e.g. a second shell member. For example, the first shell member and one or more further shell members, e.g. the second shell member, may together encompass the entire pre-formed core. The first shell member and one or more further shell members, e.g. the second shell member, may be joined together with a substantially water-tight seal.
The shell or a portion thereof may comprise one or more indicia, e.g. to indicate a brand name, to provide installation or safety instructions or to provide some surface decoration.
The shell or shell members may be of uniform thickness. The shell or shell members may have a thickness of less than 0.2 mm, or less than 0.5mm, 1mm, 2mm, 3mm, 5 mm, or a thickness of 5mm or greater. The shell or shell members may comprise regions of non-uniform thickness. For instance, the regions of non-uniform thickness may comprise anti-slip features, or may comprise weight saving features.
The shell or the shell members may comprise a softer material disposed in one or more regions underneath an outer shell material (e.g. a hard plastics material such as an acrylic), to provide impact absorption, in use. The softer material may comprise a plastics material such as acrylonitrile butadiene styrene (ABS). The ratio of the thickness of the softer material (e.g. ABS) to the outer shell material (e.g. acrylic) may be at least 5: 1 and/or up to 15: 1. For instance, the ratio of the thickness of the ABS to acrylic may be 9: 1. In an embodiment, a portion of the shell may be 2 mm thick with a skin of acrylic 0.2 mm thick and a sub-layer of ABS 1.8 mm thick. Such a portion of the shell may provide a floor for a shower tray.
At least a portion of the shell or shell members may be coated with, or have impregnated therein, an antimicrobial agent.
The shell or one or more of the shell member(s) may be bonded, e.g. adhered, to the pre-formed core. Any suitable adhesive may be used to adhere the shell or one of more of the shell member(s) to the pre-formed core.
Heat and/or pressure may be applied to the shell or one or more of the shell member(s) during bonding to the pre-formed core.
A thicker layer of adhesive may be applied to one or more regions of the pre-formed core, e.g. regions adjacent joins between two shell members. The thicker layer of adhesive may thus help to provide a watertight seal between shell members.
During manufacture, the article may be trimmed following the bonding, e.g. adhesion, of the shell or the shell members to the pre-formed core. A thicker layer of adhesive may be applied to the pre-formed core at regions where the article is to be trimmed. The thicker layer of adhesive may prevent exposure of the pre-formed core after the article has been trimmed. This may have the advantage of preventing the ingress of, for example, water, dirt, or other fluids, in use, and/or ensuring a secure bond is formed between the pre-formed core and the shell at potential regions of weakness.
The trimming process may leave the pre-formed core intact. This may have the advantage of not affecting the mechanical properties of the pre-formed core during post-processing.
The regions having thicker layers of adhesive may allow for the article of sanitary ware to be further trimmed during installation, without cutting the pre-formed core. This may have the advantage of providing an improved means of installation, which may be useful when installing the article in an area having an irregular shape and/or unusual dimensions.
The waterproof or splash-resistant article may comprise an article of sanitary ware or part thereof. The article of sanitary ware may include, for example, a bath, a sink, a toilet, a shower tray, a waterproof or splash-resistant panel for covering a surface such as a wall, floor or ceiling, a shower panel, a shower column or the like.
The waterproof or splash-resistant article, e.g. article of sanitary ware, may comprise a fluid, e.g. water, collection surface. The fluid collection surface may be configured to slope towards a waste.
A second aspect provides a pre-formed core for a waterproof or splash-resistant article, wherein the pre-formed core has a shape that reflects the shape of the waterproof or splash-resistant article, and wherein the pre-formed core comprises, or consists essentially of, a composite comprising a mix of one or more filler materials and a binder, wherein the one or more filler materials comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material (e.g. a polymeric material).
The binder may comprise a resin binder. The binder may comprise an adhesive.
One or more of the filler materials may comprise recycled material. For example, the pre-formed core may comprise used sawdust and/or wood chippings and/or wood shavings. The pre-formed core may comprise rubber crumb, e.g. recycled from used car tyres.
The shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
The pre-formed core may comprise a plurality of pre-formed core sections. In embodiments comprising a plurality of pre-formed core sections, the pre-formed core sections may be joined together to provide the pre-formed core. The pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding. The pre-formed core sections may be bonded together using an adhesive.
Additionally or alternatively, the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core. For instance, the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
The pre-formed core may comprise a unitary body.
The pre-formed core or the pre-formed core sections may include a foam or a honeycomb structure.
The pre-formed core or the pre-formed core sections may be formed by a moulding process such as a compression moulding process. The pre-formed core or the pre formed core sections may be formed by injection moulding, casting, machining or the like.
A third aspect provides an ablutionary or plumbing system comprising:
a fluid delivery device; and
a waterproof or splash-resistant article according to the first aspect, the waterproof or splash-resistant article having a fluid collection surface arranged to collect, in use, fluid emitted from the fluid delivery device.
The waterproof or splash-resistant article may comprise an article of sanitary ware. The fluid collection surface may be configured to slope towards a waste.
The fluid delivery device may comprise a faucet, a tap, a sprayer or a spray head for a shower.
The fluid may be water.
A fourth aspect provides a shower and/or bath system comprising one or more waterproof or splash-resistant articles according to the first aspect. The shower and/or bath system may comprise at least one fluid delivery device. The The fluid delivery device may comprise a faucet, a tap, a sprayer or a spray head for a shower.
The fluid may be water.
A fifth aspect provides a method of manufacture of a waterproof or splash-resistant article, e.g. a waterproof or splash-resistant article according to the first aspect, comprising:
providing a pre-formed core;
providing a shell comprising one or more pre-formed shell members;
arranging the shell member (s) at least partially around the pre-formed core; and
bonding the shell member(s) to the pre-formed core.
By employing a pre-formed core, manufacture of the article may be simplified. Also, in contrast to forming a core in situ, e.g. by curing, there may be less likelihood of the article being distorted.
The shell may define at least partially an internal volume, the internal volume having a shape and the pre-formed core may have substantially the shape of the internal volume and may occupy 90% or more of the internal volume.
The pre-formed core may occupy 95% or more, 97% or more or 98% or more of the internal volume. The pre-formed core may occupy substantially all of the internal volume.
The shape of the pre-formed core may reflect a shape of the waterproof or splash- resistant article. The shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
The method may comprise the preliminary step or steps of forming the pre-formed core and/or one or more of the pre-formed shell members. The pre-formed core may comprise a plurality of pre-formed core sections. In embodiments comprising a plurality of pre-formed core sections, the pre-formed core sections may be joined together to provide the pre-formed core. The pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding. The pre-formed core sections may be bonded together using an adhesive.
Additionally or alternatively, the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core. For instance, the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
The pre-formed core may comprise a unitary body.
The pre-formed core or pre-formed core sections may comprise, or consist essentially of, a composite comprising a mix of two or more materials.
The composite may comprise one or more filler materials mixed with a binder, e.g. a resin binder. The binder may comprise an adhesive.
The filler material(s) may comprise a wood-based material. The filler materials may comprise one or more of: wood, sawdust, wood chippings, wood shavings, rubber (e.g. rubber crumb), cork and a plastics material (e.g. a polymeric material).
One or more of the filler materials may comprise recycled material. For example, the pre-formed core or pre-formed core sections may comprise used sawdust and/or wood chippings and/or wood shavings. The pre-formed core or pre-formed core sections may comprise rubber crumb, e.g. recycled from used car tyres.
The pre-formed core or the pre-formed core sections may include a foam or honeycomb structure.
The pre-formed core or the pre-formed core sections may be formed by a moulding process such as a compression moulding process. The pre-formed core or the pre- formed core sections may be formed by injection moulding, casting, machining or the like.
By employing a pre-formed core comprising a composite comprising a mix of two or more materials such as those mentioned above, the waterproof or splash-resistant article may be relatively light, whilst having the mechanical properties required for its intended use. For example, a shower tray comprising such a pre-formed core may be considerably lighter than an equivalent polymer-concrete shower tray. Hence, such a shower tray may be more easily handled than known polymer-concrete shower trays and may even be light enough to be lifted safely by one person.
Another benefit of producing a relatively light waterproof or splash-resistant article is that the article may require less packaging, since there may be a reduced risk of sustaining damage particularly during transport and installation.
The shell may comprise, or consist essentially of, a plastics material. The plastics material may include an acrylic.
The shell may extend at least partially around the pre-formed core. The shell may encompass 50% or more of the pre-formed core. The shell may encompass the pre formed core. The shell may be substantially watertight. A portion of the pre-formed core may not be covered by the shell.
The shell may comprise a plurality of shell members. The shell or one or more of the shell member(s) may be made at least partially by any suitable moulding or forming process, e.g. vacuum forming.
A first shell member may be configured to cover at least partially or entirely a first surface of the pre-formed core. The first shell member may be adapted to provide, in use, a fluid-contacting surface, e.g. a water-contacting surface. For example, the article may comprise a shower tray and the first shell member may provide a water collection surface and a floor. The floor may be provided with one or more anti-slip features such as protrusions, ridges or roughened regions. The shell may further comprise one or more further shell members, e.g. a second shell member. For example, the first shell member and one or more further shell members, e.g. the second shell member, may together encompass the entire pre-formed core. The first shell member and one or more further shell members, e.g. the second shell member, may be joined together with a substantially water-tight seal.
The shell or a portion thereof may comprise one or more indicia, e.g. to indicate a brand name, to provide installation or safety instructions or to provide some surface decoration.
The shell or shell members may be of uniform thickness. The shell or shell members may have a thickness of less than 0.2 mm, or less than 0.5mm, 1mm, 2mm, 3mm, 5 mm, or a thickness of 5mm or greater. The shell or shell members may comprise regions of non-uniform thickness. For instance, the regions of non-uniform thickness may comprise anti-slip features, or may comprise weight saving features.
The shell or the shell members may comprise a softer material disposed in one or more regions underneath an outer shell material (e.g. a hard plastics material such as an acrylic), to provide impact absorption, in use. The softer material may comprise a plastics material such as acrylonitrile butadiene styrene (ABS).
The ratio of the thickness of the softer material (e.g. ABS) to the outer shell material (e.g. acrylic) may be at least 5: 1 and/or up to 15: 1. For instance, the ratio of the thickness of the ABS to acrylic may be 9: 1. In an embodiment, a portion of the shell may be 2 mm thick with a skin of acrylic 0.2 mm thick and a sub-layer of ABS 1.8 mm thick Such a portion of the shell may provide a floor for a shower tray.
At least a portion of the shell or shell members may be coated with, or have impregnated therein, an antimicrobial agent.
Any suitable adhesive may be used to bond the shell member(s) to the pre-formed core.
Heat and/or pressure may be applied to the shell member(s) during bonding to the pre formed core. A thicker layer of adhesive may be applied to one or more regions of the pre-formed core, e.g. regions adjacent joins between two shell members. The thicker layer of adhesive may thus help to provide a watertight seal between shell members.
During manufacture, the article may be trimmed following the bonding, e.g. adhesion, of the shell member(s) to the pre-formed core. A thicker layer of adhesive may be applied to the pre-formed core at regions where the article is to be trimmed. The thicker layer of adhesive may prevent exposure of the pre-formed core after the article has been trimmed. This may have the advantage of preventing the ingress of, for example, water, dirt, or other fluids, in use, and/or ensuring a secure bond is formed between the pre-formed core and the shell at potential regions of weakness.
The trimming process may leave the pre-formed core intact. This may have the advantage of not affecting the mechanical properties of the pre-formed core during post-processing.
The regions having thicker layers of adhesive may allow for the article of sanitary ware to be further trimmed during installation, without cutting the pre-formed core. This may have the advantage of providing an improved means of installation, which may be useful when installing the article in an area having an irregular shape and/or unusual dimensions.
The waterproof or splash-resistant article may comprise an article of sanitary ware or part thereof. The article of sanitary ware may include, for example, a bath, a sink, a toilet, a shower tray, a waterproof or splash-resistant panel for covering a surface such as a wall, floor or ceiling, a shower panel, a shower column or the like.
The waterproof or splash-resistant article, e.g. article of sanitary ware, may comprise a fluid collection surface. The fluid collection surface may be configured to slope towards a waste.
The method may further comprise trimming the article to provide an intended shape.
The method may comprise applying a decorative layer or coating. The method may further comprise a step of applying a coating, e.g. a gel coating, to a surface of the pre-formed core.
A sixth aspect provides a method of manufacture of a waterproof or splash-resistant article, e.g. a waterproof or splash-resistant article according to the first aspect, comprising:
providing a pre-formed core; and
forming a shell on the pre-formed core, wherein at least a portion of the shell is formed by applying a coating on to a surface of the preformed core.
The shell may define at least partially an internal volume, the internal volume having a shape and the pre-formed core may have substantially the shape of the internal volume and may occupy 90% or more of the internal volume.
The shell may be formed at least partially by gel coating. Gel coating may include application of a gel on to at least a portion of the pre-formed core and/or on to at least a portion of the shell or one or more of the shell member(s) by means of spraying, pouring or any other suitable method.
A seventh aspect provides a method of manufacture of a pre-formed core for a waterproof or splash-resistant article, e.g. a pre-formed core according to the second aspect, the pre-formed core having a shape that reflects the shape of the waterproof or splash-resistant article, comprising:
providing a mix of one or more filler materials and a binder, wherein the one or more filler materials comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material;
and forming the pre-formed core from the mix.
The pre-formed core may be formed by a moulding process such as a compression moulding process. The pre-formed core or the pre-formed core sections may be formed by injection moulding, casting, machining or the like.
The binder may comprise a resin binder. The binder may comprise an adhesive. One or more of the filler materials may comprise recycled material. For example, the pre-formed core may comprise used sawdust and/or wood chippings and/or wood shavings. The pre-formed core may comprise rubber crumb, e.g. recycled from used car tyres.
The shape of the pre-formed core may be the same as, substantially the same as or similar to the shape of the waterproof or splash-resistant article.
The pre-formed core may comprise a plurality of pre-formed core sections. In embodiments comprising a plurality of pre-formed core sections, the pre-formed core sections may be joined together to provide the pre-formed core. The pre-formed core sections may be joined together by any suitable means, e.g. using mechanical fasteners and/or chemical bonding. The pre-formed core sections may be bonded together using an adhesive.
Additionally or alternatively, the pre-formed core sections may be configured to interlock with each other to provide the pre-formed core. For instance, the pre-formed core sections may comprise cooperating interlocking features to enable each pre formed core section to be attached securely to one or more adjacent pre-formed core sections.
The pre-formed core may comprise a unitary body.
The pre-formed core or the pre-formed core sections may include a foam or a honeycomb structure.
Example embodiments will now be described with reference to the accompanying drawings, in which:
Figure 1 is an exploded view of an example shower tray;
Figure 2 is a cross-sectional view through the pre-formed components of the shower tray of Figure 1;
Figure 3a is a cross-sectional view through a region near the waste of the example shower tray prior to any trimming process; Figure 3b is a cross-sectional view through the region near the waste of the shower tray as illustrated in Figure 3b after a trimming process;
Figure 4a is a cross-sectional view through an edge region of the example shower tray prior to any trimming process;
Figure 4b is a cross-sectional view through the edge region of the example shower tray as illustrated in Figure 4a after a trimming process;
Figure 5 is a cross-sectional view of a pre-formed core for a bath; and
Figure 7 is a flow chart of an example embodiment of a method of manufacture of an article of sanitary ware.
Figure 1 is an exploded view of a shower tray 1 . The shower tray l is a square shower tray. It will be appreciated, however, that the shower tray 1 may have any other general form, e.g. a rectangular or non-rectangular shape .
The shower tray 1 comprises a floor 2 and inner walls 3 defining a well for collecting water dispensed from a shower head (not shown) and confining the collected water to the shower tray 1 . The floor 2 may be provided with an anti-slip surface (not shown), which may for example comprise a plurality of raised ribs arranged in any suitable pattern. A hole 4 is provided at an edge of the floor 2 for a waste pipe (not shown) . The hole 4 may be located at any location within the floor 2. The floor 2 has a slope with a gradient of at least 1 ° towards the hole 4 so that water in the shower tray 1 will self-drain towards the hole 4.
The inner walls 3 lead to an outwardly extending upper surface 27 at the top of the shower tray 1 , thereby forming a rim 30 that extends around the floor 2 on all four sides. The outwardly extending upper wall 27 may be substantially horizontal. The outwardly extending upper wall may lead to an upstand (not shown) at the outer peripheral edge of the shower tray 1.
The shower tray 1 has a pattern of strengthening ribs 32 on an intended underside thereof.
Outer walls 5 extend downwardly from an outer edge of the rim 30 to a skirt 34. The skirt 34 extends around the periphery of the shower tray 1. The skirt 34 may be removed in a trimming step during manufacture of the shower tray 1. The shower tray 1 comprises a shell 9 and a pre-formed core 10. The shell 9 encompasses the pre-formed core 10. The shell 9 comprises a first shell member 6 and a second shell member 8. The first shell member 6 constitutes an upper shell member. The second shell member 8 constitutes a lower shell member. The first shell member 6 and/or the second shell member 8 may be vacuum formed. The shell 9 formed by the first shell member 6 and the second shell member 8 has an internal volume.
The pre-formed core 10 has substantially the same shape as the shower tray 1. The pre-formed core 10 occupies more than 95% of the internal volume defined by the shell 9. Hence, the pre-formed core 10 provides the shower tray 1 with structural integrity. The pre-formed core 10 comprises a single body. The pre-formed core is made of a composite comprising one or more filler materials mixed with a binder. Conveniently, the filler material(s) may comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material. The binder may comprise an adhesive. For example, the pre-formed core 10 may comprise, or consist essentially of, a composite made up of a wood-based filler material such as sawdust, wood chippings and/or wood shavings and an adhesive binder. The pre-formed core may be formed by a compression moulding process. In an alternative embodiment, the pre-formed core 10 may be formed of a plurality of pre-formed core sections. The pre-formed core sections may be joined together and/or may be configured to interlock with each other.
The first shell member 6 provides an upper surface of the shower tray 1. The upper surface of the shower tray 1 includes a water collection surface including the floor 2.
The second shell member 8 provides a lower surface of the shower tray 1. The lower surface of the shower tray 1 includes the pattern of strengthening ribs 32. The lower surface of the shower tray is provided with a plurality of attachment points 36 for the attachment of feet (not shown). The pre-formed core 10 is adhered to the first shell member 6 and the second shell member 8. Heat and/or pressure may be applied to the shell or the shell members during adhesion of the shell or the shell members to the pre-formed core.
An example method of manufacture of the shower tray 1 will now be described with reference to Figures 2, 3a, 3b, 4a and 4b.
Referring to Figure 2, the pre-formed first shell member 6 is held upside down. An adhesive is applied to an inner surface of the first shell member 6, e.g. by spraying. The pre-formed core 10 is then placed within the first shell member 6. The pre formed second shell member 8, with adhesive applied to an inner surface thereof, is then put in place over the pre-formed core 10 such that the shell 9 formed by the first shell member 6 and the second shell member 8 completely encompasses the pre formed core 10. Additionally or alternatively, adhesive may be applied to one or more surfaces of the pre-formed core 10. A thicker layer of adhesive may be applied at regions where trimming is to take place, for example in a region near the waste 4 and/or a region near the outer wall 5 and the skirt 34, as will be described with reference to Figures 3a, 3b, 4a, 4b. Heat and/or pressure may be applied to promote adhesion between the first and second shell members 6, 8 and the pre-formed core 10.
Figures 3a and 3b show in cross-section a region near the waste 4, before (Figure 3a) and after (Figure 3b) trimming along a trim line indicated by a dashed line 24.
A layer of adhesive 20 is shown, which adheres the second core member 8 to the pre formed core 10. In the region where the waste 4 will be provided, the layer of adhesive 20 adheres the second shell member 8 to the first shell member 6. In a region around the waste 4, a thicker layer of adhesive 22 is provided.
The trim line 24 is disposed a little below an underside of the second shell member 8. The trim line 24 passes through a lower portion of, or just beneath, the thicker layer of adhesive 22. After trimming (Figure 3b), the layer of adhesive 20 is exposed proximal the thicker layer of adhesive 22 between an edge of the first shell member 6 and an edge of the second shell member 8. The thicker layer of adhesive 22 ensures that a water-tight seal protecting the pre-formed core 10 is maintained after trimming. Figures 4a and 4b show in cross-section an edge region of the shower tray 1, before (Figure 4a) and after (Figure 4b) trimming along a trim line indicated by a dashed line 44. The layer of adhesive 20 is shown, which adheres the second core member 8 to the pre-formed core 10. Towards the bottom of the outer wall 5 and the skirt 34, the layer of adhesive 20 adheres the second shell member 8 to the first shell member 6. In an region around a lower corner of the pre-formed core 10, a thicker layer of adhesive 42 is provided.
The trim line 44 is disposed a little below an underside of the second shell member 8. The trim line 44 passes through a lower portion of, or just beneath, the thicker layer of adhesive 42. After trimming (Figure 4b), the layer of adhesive 20 is exposed proximal to the thicker layer of adhesive 42 between an edge of the first shell member 6 and an edge of the second shell member 8. The thicker layer of adhesive 42 ensures that a water-tight seal protecting the pre-formed core 10 is maintained after trimming.
Figure 5 shows in cross-section a pre-formed core 50 for a bath. The pre-formed core 50 has a shape which reflects the shape of the bath. The bath would comprise a shell (not shown) comprising one or more shell members. The pre-formed core 50 would occupy 90% or more of an internal volume defined at least partially by the shell.
The pre-formed core 50 comprises a first pre-formed core section 51 and a second pre formed core section 52. The first pre-formed core section 51 includes a side portion 55 and a base portion 57. The second pre-formed core section 52 includes a side portion 54 and a base portion 56. The second pre-formed core section 52 is a mirror image of the first pre-formed core section 51.
The first pre-formed core section 51 is adhered to the second pre-formed core section 52 at a join 53. The join 53 extends in longitudinal direction and is located at a midpoint of the base portion of the pre-formed core 50.
The first and second pre-formed core sections 51, 52 are each made of a composite comprising one or more filler materials mixed with a binder. Conveniently, the filler material(s) may comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material. The binder may comprise an adhesive.
For example, the first and second pre-formed core sections 51, 52 may comprise, or consist essentially of, a composite made up of a wood-based filler material such as sawdust, wood chippings and/or wood shavings and an adhesive binder. The first and second pre-formed core sections 51, 52 may be formed by a compression moulding process.
Figure 6 is a flow chart illustrating an example method of manufacture of a waterproof or splash-resistant article such as the shower tray 1.
A first step 601 includes providing a pre-formed core. The pre-formed core may be as described herein and may have been manufactured by any suitable process, e.g. a compression moulding process. The pre-formed core may comprise, or consist essentially of, a composite comprising a mix of a wood-based filler material (e.g. sawdust, wood chippings or wood shavings) and a resin binder.
A second step 602 includes providing a shell. The shell may comprise a plurality of shell members. The shell or shell members may be pre-formed, e.g. by vacuum forming. The shell or shell members may comprise a plastics material such as an acrylic.
A third step 603 includes adhering the shell or shell members to the pre-formed core. Any suitable adhesive may be applied to the pre-formed core and/or the shell or shell members by any suitable means, e.g. by spraying. Heat and/or pressure may be applied to the shell or the shell members during adhesion of the shell or the shell members to the pre-formed core. A thicker layer of adhesive may be applied at regions where trimming is to take place.
A fourth step 604 includes trimming the shell or shell portions to provide an article having the intended shape of waterproof or splash-resistant article.
The method of manufacture may comprise one or more additional machining or finishing steps. In embodiments, at least a portion of the shell may be provided by applying a coating to the pre-formed core. A gel coating process may be used to apply the coating to the pre-formed core. It will be understood that the invention is not limited to the embodiments described above. Various modifications and improvements can be made without departing from the concepts disclosed herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to all combinations and sub-combinations of one or more features disclosed herein.

Claims

1. A waterproof or splash-resistant article comprising a shell defining at least partially an internal volume, the internal volume having a shape; and a pre-formed core, wherein the pre-formed core has substantially the shape of the internal volume and the pre-formed core occupies 90% or more of the internal volume.
2. An article according to claim 1, wherein the pre-formed core occupies 95% or more, 97% or more or 98% or more of the internal volume.
3. An article according to claim 1 or claim 2, wherein the shape of the pre-formed core reflects a shape of the waterproof or splash-resistant article
4. An article according to claim 1, claim 2 or claim 3, wherein the pre-formed core comprises a plurality of pre-formed core sections.
5. An article according to any one of claims 1 to 4, wherein the pre-formed core comprises, or consists essentially of, a composite comprising a mix of two or more materials comprising one or more filler materials mixed with a binder.
6. An article according to claim 5, wherein the filler material(s) comprise a wood-based material or one or more of: wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material.
7. An article according to claim 6 or claim 7, wherein one or more of the filler materials comprises recycled material.
8. An article according to any one of the preceding claims, wherein the shell comprises, or consists essentially of, a plastics material.
9. An article according to any one of the preceding claims, wherein the shell encompasses 50% or more of the pre-formed core.
10. An article according to any one of the preceding claims, wherein the shell comprises one or more shell members, e.g. a plurality of shell members.
11. An article according to claim 10, wherein the shell member(s) is/are pre formed.
12. An article according to any one of the preceding claims, wherein the shell or one or more shell members is/are formed directly on to the pre-formed core.
13. An article according to any one of the preceding claims, wherein the shell or one or more of the shell members is/are bonded, e.g. adhered, to the pre-formed core.
14. An article according to any one of the preceding claims, wherein the waterproof or splash-resistant article comprises an article of sanitary ware or part thereof.
15. An article according to claim 14, wherein the article of sanitary ware includes a bath, a sink, a toilet, a shower tray, a waterproof or splash-resistant panel for covering a surface such as a wall, floor or ceiling, a shower panel or a shower column.
16. A pre-formed core for a waterproof or splash-resistant article, wherein the pre formed core has a shape that reflects the shape of the waterproof or splash-resistant article, and wherein the pre-formed core comprises, or consists essentially of, a composite comprising a mix of one or more filler materials and a binder, wherein the one or more filler materials comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material.
17. An ablutionary or plumbing system comprising:
a fluid delivery device; and
a waterproof or splash-resistant article according to any one of claims 1 to 17, the waterproof or splash-resistant article having a fluid collection surface arranged to collect, in use, fluid emitted from the fluid delivery device.
18. A shower and/or bath system comprising one or more waterproof or splash- resistant articles according to any one of claims 1 to 15.
19. A method of manufacture of a waterproof or splash-resistant article, e.g. a waterproof or splash-resistant article according to any one of claims 1 to 17, comprising:
providing a pre-formed core;
providing a shell comprising one or more pre-formed shell members;
arranging the shell member (s) at least partially around the pre-formed core; and
bonding the shell member(s) to the pre-formed core.
20. A method according to claim 19 comprising the preliminary step or steps of forming the pre-formed core and/or one or more of the pre-formed shell members.
21. A method according to claim 19 or claim 20, wherein the pre-formed core is formed by a moulding process such as a compression moulding process.
22. A method according to claim 19, claim 20 or claim 21, wherein the article is trimmed following the bonding, e.g. adhesion, of the shell member(s) to the pre formed core.
23. A method according to claim 22, wherein a thicker layer of adhesive is applied to the pre-formed core at regions where the article is to be trimmed.
24. A method of manufacture of a waterproof or splash-resistant article, e.g. a waterproof or splash-resistant article according to any one of claims 1 to 15, comprising:
providing a pre-formed core; and
forming a shell on the pre-formed core, wherein at least a portion of the shell is formed by applying a coating on to a surface of the preformed core.
25. A method of manufacture of a pre-formed core for a waterproof or splash- resistant article, e.g. a pre-formed core according to claim 16, the pre-formed core having a shape that reflects the shape of the waterproof or splash-resistant article, comprising: providing a mix of one or more filler materials and a binder, wherein the one or more filler materials comprise one or more of: a wood-based material, wood, sawdust, wood chippings, wood shavings, rubber, cork and a plastics material;
and forming the pre-formed core from the mix.
EP20723496.4A 2019-06-24 2020-04-24 Waterproof or splash-resistant article Pending EP3986221A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1908990.3A GB2585006B (en) 2019-06-24 2019-06-24 Waterproof or splash-resistant article
PCT/GB2020/051016 WO2020260851A2 (en) 2019-06-24 2020-04-24 Waterproof or splash-resistant article

Publications (1)

Publication Number Publication Date
EP3986221A2 true EP3986221A2 (en) 2022-04-27

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ID=67511778

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20723496.4A Pending EP3986221A2 (en) 2019-06-24 2020-04-24 Waterproof or splash-resistant article

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EP (1) EP3986221A2 (en)
GB (1) GB2585006B (en)
WO (1) WO2020260851A2 (en)

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB0317438D0 (en) 2003-07-25 2003-08-27 Kohler Mira Ltd Composite article and method of manufacture
GB2471687A (en) * 2009-07-08 2011-01-12 Polymer Recovery Ltd A shower floor structure with support layer
GB2482030B (en) * 2010-07-16 2015-11-04 Acell Ind Ltd Composite materials and uses thereof
GB2482492A (en) * 2010-08-03 2012-02-08 Jet Ltd Spa Reinforced shower tray
ES2389421B2 (en) * 2011-02-10 2013-05-30 Hidronatur, S.L. PROCEDURE FOR OBTAINING OBJECTS OR PADDED ITEMS APPLICABLE TO SHOWER TRAYS AND BATHROOMS.
US9179807B2 (en) * 2012-09-14 2015-11-10 Sonoco Development, Inc. Support for shower pan or tub
FR3042147B1 (en) * 2015-10-12 2017-12-22 Asm METHOD FOR MANUFACTURING A SHOWER RECEIVER BIN FROM A COMPOSITE PANEL
CN108634837A (en) * 2018-07-03 2018-10-12 珠海兴业绿色建筑科技有限公司 A kind of water-proof chassis of integral bathroom

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WO2020260851A3 (en) 2021-05-27
GB2585006A (en) 2020-12-30
GB2585006B (en) 2022-06-15
GB201908990D0 (en) 2019-08-07
WO2020260851A2 (en) 2020-12-30

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Inventor name: NICHOLS, JOHN