GB2469662A - A shower tray of woven fabric in a resin polymer matrix - Google Patents
A shower tray of woven fabric in a resin polymer matrix Download PDFInfo
- Publication number
- GB2469662A GB2469662A GB0906920A GB0906920A GB2469662A GB 2469662 A GB2469662 A GB 2469662A GB 0906920 A GB0906920 A GB 0906920A GB 0906920 A GB0906920 A GB 0906920A GB 2469662 A GB2469662 A GB 2469662A
- Authority
- GB
- United Kingdom
- Prior art keywords
- mould
- layers
- shower tray
- resin
- fibres
- 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.)
- Withdrawn
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 25
- 239000011347 resin Substances 0.000 title claims abstract description 25
- 239000011159 matrix material Substances 0.000 title claims abstract description 8
- 229920000642 polymer Polymers 0.000 title claims abstract description 8
- 239000002759 woven fabric Substances 0.000 title abstract 3
- 239000003365 glass fiber Substances 0.000 claims abstract description 21
- 238000000034 method Methods 0.000 claims abstract description 12
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 8
- 239000002131 composite material Substances 0.000 claims abstract description 7
- 239000000835 fiber Substances 0.000 claims abstract description 7
- 239000011167 3D woven fabric Substances 0.000 claims abstract description 6
- 239000003822 epoxy resin Substances 0.000 claims abstract description 5
- 229920000647 polyepoxide Polymers 0.000 claims abstract description 5
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 3
- 241000208202 Linaceae Species 0.000 claims abstract description 3
- 235000004431 Linum usitatissimum Nutrition 0.000 claims abstract description 3
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 3
- 238000009736 wetting Methods 0.000 claims abstract description 3
- 239000004744 fabric Substances 0.000 claims description 10
- 238000007666 vacuum forming Methods 0.000 claims description 3
- 238000005096 rolling process Methods 0.000 claims description 2
- 235000004879 dioscorea Nutrition 0.000 description 3
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000009787 hand lay-up Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/083—Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/769—Sanitary equipment
- B29L2031/7696—Showers
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Public Health (AREA)
- Epidemiology (AREA)
- General Health & Medical Sciences (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
The invention relates to a shower tray 10 formed from a composite material comprising at least one layer of 3D-woven fabric 32 embedded in a polymer matrix. The woven fabric may comprise at least two orthogonally woven layers of fibres linked by warp and or weft fibres extending through the structure between the layers to bind them into a three dimensional structure. The fibres may be glass fibre, carbon fibre, flax, natural or man made fibres. The polymer matrix may be a thermosetting epoxy resin. A later embodiment relates to a method for making said shower tray comprising the steps of; applying a release agent to a mould, applying thermosetting resin to the mould, placing at least one layer a layer of chopped strand fibre mat 26, 28 over the mould, applying a layer of the three dimensional woven fabric over the mould and wetting the layers with resin.
Description
Shower Tray This invention relates to a composite shower tray, and in particular to a preformed composite shower tray for use in wet room applications.
Shower trays are used to collect water beneath a shower and typically comprise a thermoformed plastic or fibre reinforced plastic moulded tray having a central depression provided with a drain outlet. The tray is typically supported on timber or foam supports.
Recent trends have seen an increased popularity in wet room showers, where a much larger shower tray area is required due to a lack of shower enclosure. Such wet room arrangements are particularly popular for disabled users because they allow a person to more easily access the shower and permit wheelchair access to the shower. However, traditional thermoformed plastic or glass reinforced plastic moulded trays of sufficient size for wet room applications require complex supporting structures and/or require substantial thickness and/or reinforcement structures due to their large size and substantial unsupported surface areas.
This results in a shower tray that is very heavy and difficult to manoeuvre. There is therefore a desire to provide a large preformed moulded shower tray that provides sufficient rigidity for wet room applications while alleviating the problems or increased weight and resultant handling, transportation and installation difficulties.
According to a first aspect of the present invention there is provided a shower tray formed from a composite material comprising at least one layer of 3D-woven fabric embedded in a polymer matrix.
3D-woven fibre reinforced composite structures can provide much greater rigidity and strength than existing layered non-woven glass fibre reinforced plastic structures.
In a preferred embodiment said 3D-woven fabric comprises at least two orthogonally woven layers of fibres linked by warp and/or well fibres extending through the structure between said layers to bind said layers into a 3D-woven structure. Preferably said linking fibres extend through and between said layers in a direction substantially perpendicular to said layers. The fibres may comprise glass fibres. Alternatively other suitable man made or natural fibre reinforcing yams may be used, such as carbon fibre or flax.
Said polymer matrix may comprise a thermosetting resin, such as an epoxy resin.
Said show tray may be formed from one or more further layers of non-woven fibre mat embedded in a polymer matrix to define a laminated structure. An outer layer, preferably an upper layer, of the shower tray may comprise a gel coat, preferably coloured to provide a desired surface finish.
According to a further aspect of the present invention there is provided a process for making a shower tray comprising providing a mould having a shape corresponding to the upper surface of the finished shower tray, applying a release agent to the mould, applying an uncured thermosetting resin to the mould and placing at least one layer of chopped strand glass fibre mat over the mould and subsequently applying a layer of 3D woven glass fibre fabric over the mould and wetting said layers throughout with further resin.
Preferably the method comprises the further step of applying one or more further layers of chopped strand glass fibre mat over the mould, or onto a lid of the mould before placing said lid over the mould, applying further resin as required to wet through the layers.
Air may be removed from the layers by rolling. In an alternative embodiment, the layers of resin wetted non-woven and 3D woven glass fibre may be placed into the mould and the mould may be evacuated before resin is injected into the mould in a vacuum forming process.
An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:-Figure 1 is a perspective view of a shower tray in accordance with the present invention; Figure 2 is a plan view of the shower tray of Figure 1; Figure 3 is a sectional view through the shower tray of Figure 1.
As shown in the drawings, a shower tray 10 in accordance with the present invention comprises a substantially rectangular planar body having an outer border edge 12 surrounding a tray surface having a plurality of downwardly sloping facets 14,16,18,20 that meet in a circular aperture 22 for connection to a drain outlet. While the embodiment shown comprises a rectangular tray, any other desired shape of tray may be provided, for example square, circular, oval or any other desired shape.
The outer border edge 12 comprises a fixing frame having a plurality of fixing holes 24 to allow the tray to be fastened to an underlying structure, such as a frame of wooden supports.
As shown in Figure 3, the tray 10 is formed from a laminated composite material comprising two upper layers of chopped strand unwoven glass fibre mat 26, 28, a lower layer chopped strand unwoven glass fibre mat 30 and a layer of 3D woven glass fibre fabric 32 interposed between the upper and lower layers. The various layers of glass fibre mat and fabric are impregnates and bonded together by a thermosetting resin, such as epoxy resin. A coloured gelcoat may be provided on at least the upper surface of the shower tray.
The 3D glass fibre fabric 32 comprises two layers of orthogonally woven fibres linked by vertical yams. These vertical yams are woven into the layers thus forming an integral sandwich structure. We can distinguish two directions in the fabric, namely warp and weft.
The 3D woven fabric is supplied in a roll and the warp direction can be recognised as extending along the length of the roll while the weft direction can be recognised as extending across the width of the roll. When the 3D fabric is impregnated with a thermosetting resin, the fabric absorbs the resin and, due to the capillary forces of the yarns, the fabric rises to a predetermined height as the gap between the layers is filled with resin.
By this process, a lightweight and strong sandwich laminate is formed that offers excellent mechanical properties.
The shower tray 10 may be made by forming the tray using a hand lay-up operation. A mould is provided having a shape corresponding to the upper surface of the finished shower tray. The mould is a negative image of the tray to be formed. A release agent is applied to the mould and then a white gelcoat is applied (although other colours could be used as desired).
Epoxy resin is mixed with a catalyst and the mould is wefted out with the mixture. Next a first layer of chopped strand glass fibre mat is placed over the mould and rolled down into the mould using steel rollers. A second layer of chopped strand glass fibre is then applied to the mould and additional resin is applied. Next a layer of 3D woven glass fibre fabric of the type described above is placed over the mould and wetted throughout with further resin.
Rollers are used to ensure that the resin is applied through the layers and that all air pockets are removed.
A further layer of chopped strand glass fibre mat is placed over a lid of the mould and wetted through with resin, rollers being used remove all air pockets, and the lid is inverted and clamped over the main body of the mould. Once the resin has cured, the finished shower tray is removed from the mould. The tray may be separated from the mould using wedges. The edges of the tray may be trimmed if required.
In an alternative embodiment the tray may be formed in a vacuum forming process, wherein the resin is injected into the mould after air has been removed from the mould.
The invention is not limited to the embodiment(s) described herein but can be amended or modified without departing from the scope of the present invention.
Claims (9)
- Claims 1. A shower tray formed from a composite material comprising at least one layer of 3D-woven fabric embedded in a polymer matrix.
- 2. A shower tray as claimed in claim 1, wherein said 3D-woven fabric comprises at least two orthogonally woven layers of fibres linked by warp and/or weft fibres extending through the structure between said layers to bind said layers into a 3D-woven structure.
- 3. A shower tray as claimed in claim 2, wherein said linking fibres extend through and between said layers in a direction substantially perpendicular to said layers.
- 4. A shower tray as claimed in claim 2 or claim 3, wherein the fibres comprise glass fibres, carbon fibre or flax or any suitable man made or natural fibres.
- 5. A shower tray as claimed in any preceding claim, wherein aid polymer matrix comprises a thermosetting resin, such as an epoxy resin.
- 6. A process for making a shower tray comprising providing a mould having a shape 20 corresponding to the upper surface of the finished shower tray, applying a release agent to the mould, applying an uncured thermosetting resin to the mould and placing at least one layer of chopped strand glass fibre mat over the mould and subsequently applying a layer of 3D woven glass fibre fabric over the mould and wetting said layers throughout with further resin. (\J
- 7. A process as claimed in claim 6, wherein the method comprises the further step of applying one or more further layers of chopped strand glass fibre mat over the mould, or onto a lid of the mould before placing said lid over the mould, applying further resin as required to wet through the layers.
- 8. A process as claimed in claim 7, wherein air is removed from the layers by rolling.
- 9. A process as claimed in claim 6, wherein the layers of resin, wetted non-woven and 3D woven glass fibre are placed into the mould and the mould is evacuated before resin is injected into the mould in a vacuum forming process.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0906920A GB2469662A (en) | 2009-04-23 | 2009-04-23 | A shower tray of woven fabric in a resin polymer matrix |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0906920A GB2469662A (en) | 2009-04-23 | 2009-04-23 | A shower tray of woven fabric in a resin polymer matrix |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB0906920D0 GB0906920D0 (en) | 2009-06-03 |
| GB2469662A true GB2469662A (en) | 2010-10-27 |
Family
ID=40774790
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0906920A Withdrawn GB2469662A (en) | 2009-04-23 | 2009-04-23 | A shower tray of woven fabric in a resin polymer matrix |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2469662A (en) |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2482492A (en) * | 2010-08-03 | 2012-02-08 | Jet Ltd Spa | Reinforced shower tray |
| GB2486270A (en) * | 2010-12-10 | 2012-06-13 | Marleton Group Ltd | Improvements in or relating to a shower base |
| ES2389421A1 (en) * | 2011-02-10 | 2012-10-26 | Hidronatur, S.L. | Procedure for the obtainment of objects or padded elements applicable to shower trays and bathrooms. (Machine-translation by Google Translate, not legally binding) |
| EP2644375A1 (en) * | 2012-03-30 | 2013-10-02 | Chao Yang Chen | Composite board |
| ES2608698A1 (en) * | 2017-03-15 | 2017-04-12 | Forms And Design In Shower Tray Sl | Procedure for obtaining a sanitary application for the bath with melamine finish and product obtained (Machine-translation by Google Translate, not legally binding) |
| FR3042147A1 (en) * | 2015-10-12 | 2017-04-14 | Asm | METHOD FOR MANUFACTURING A SHOWER RECEIVER BIN FROM A COMPOSITE PANEL |
| CN106584881A (en) * | 2016-11-28 | 2017-04-26 | 北京卫星制造厂 | Hollow cap-shaped *-shaped reinforced all-carbon fibre structure and preparation method thereof |
| CN110315782A (en) * | 2019-07-01 | 2019-10-11 | 广东科筑住宅集成科技有限公司 | A kind of glass reinforced plastic bottom plate automatic assembly line |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2361637A (en) * | 2000-04-12 | 2001-10-31 | Creative Healthcare Ltd | Non-slip flooring for shower installation |
-
2009
- 2009-04-23 GB GB0906920A patent/GB2469662A/en not_active Withdrawn
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2361637A (en) * | 2000-04-12 | 2001-10-31 | Creative Healthcare Ltd | Non-slip flooring for shower installation |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2482492A (en) * | 2010-08-03 | 2012-02-08 | Jet Ltd Spa | Reinforced shower tray |
| GB2486270A (en) * | 2010-12-10 | 2012-06-13 | Marleton Group Ltd | Improvements in or relating to a shower base |
| ES2389421A1 (en) * | 2011-02-10 | 2012-10-26 | Hidronatur, S.L. | Procedure for the obtainment of objects or padded elements applicable to shower trays and bathrooms. (Machine-translation by Google Translate, not legally binding) |
| EP2644375A1 (en) * | 2012-03-30 | 2013-10-02 | Chao Yang Chen | Composite board |
| FR3042147A1 (en) * | 2015-10-12 | 2017-04-14 | Asm | METHOD FOR MANUFACTURING A SHOWER RECEIVER BIN FROM A COMPOSITE PANEL |
| EP3155943A1 (en) * | 2015-10-12 | 2017-04-19 | Asm | Method for manufacturing a shower tray from a composite panel |
| CN106584881A (en) * | 2016-11-28 | 2017-04-26 | 北京卫星制造厂 | Hollow cap-shaped *-shaped reinforced all-carbon fibre structure and preparation method thereof |
| CN106584881B (en) * | 2016-11-28 | 2018-10-09 | 北京卫星制造厂 | Full carbon fiber structural of a kind of hollow out hat shape rice word reinforcement and preparation method thereof |
| ES2608698A1 (en) * | 2017-03-15 | 2017-04-12 | Forms And Design In Shower Tray Sl | Procedure for obtaining a sanitary application for the bath with melamine finish and product obtained (Machine-translation by Google Translate, not legally binding) |
| CN110315782A (en) * | 2019-07-01 | 2019-10-11 | 广东科筑住宅集成科技有限公司 | A kind of glass reinforced plastic bottom plate automatic assembly line |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0906920D0 (en) | 2009-06-03 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |