GB2486270A - Improvements in or relating to a shower base - Google Patents
Improvements in or relating to a shower base Download PDFInfo
- Publication number
- GB2486270A GB2486270A GB1020988.0A GB201020988A GB2486270A GB 2486270 A GB2486270 A GB 2486270A GB 201020988 A GB201020988 A GB 201020988A GB 2486270 A GB2486270 A GB 2486270A
- Authority
- GB
- United Kingdom
- Prior art keywords
- castable
- support mould
- shower
- shower base
- layer
- 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- Withdrawn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
- 239000010410 layer Substances 0.000 claims abstract description 34
- 238000000034 method Methods 0.000 claims abstract description 29
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 22
- 239000002344 surface layer Substances 0.000 claims abstract description 10
- 230000009969 flowable effect Effects 0.000 claims description 16
- 239000002986 polymer concrete Substances 0.000 claims description 14
- 238000005266 casting Methods 0.000 claims description 7
- 229920003023 plastic Polymers 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 2
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 claims 1
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims 1
- 238000003780 insertion Methods 0.000 claims 1
- 230000037431 insertion Effects 0.000 claims 1
- 239000012466 permeate Substances 0.000 claims 1
- 238000009736 wetting Methods 0.000 claims 1
- 239000007788 liquid Substances 0.000 description 7
- 230000009286 beneficial effect Effects 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 3
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000009408 flooring Methods 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000002351 wastewater Substances 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 229920002457 flexible plastic Polymers 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229920003002 synthetic resin Polymers 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
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
-
- 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
-
- 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
- Health & Medical Sciences (AREA)
- Public Health (AREA)
- Engineering & Computer Science (AREA)
- Epidemiology (AREA)
- General Health & Medical Sciences (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Bathtubs, Showers, And Their Attachments (AREA)
Abstract
A method of forming a shower base 10, comprises the steps of : a) providing a support mould defining an upper surface of the shower base 10; b) placing an upper surface layer 26 of the shower base 10 in the support mould; c) pouring a flowing settable cast material into the support mould onto the upper surface layer 26; d) positioning a reinforcing flexible cast layer 34 in the support mould; and e) closing the support mould with a closure element whilst the flowing cast material sets. A shower base 10 formed using the said method is also provided.
Description
Improvements In Or Relating To A Shower Base The present invention relates to a shower base, and more particularly but not necessarily exclusively to a shower tray. The invention also relates to a method of forming said shower base.
Shower trays are well known, and come in many different types and sizes. Many methods of construction are also used. A cast shower tray tends to be very strong in compression, but can be weaker in tension. If it is dropped or an item is accidentally dropped onto it, it is easily damaged, thereby requiring replacement. As such, cast shower trays often include further external reinforcing wooden sheets which are bonded to the finished under surface of the tray post-casting. This makes the tray bulkier and heavier.
Furthermore, a cast shower tray can be extremely heavy in its own right, even without the reinforcing wooden sheets, making it difficult to store, transport and install.
The present invention seeks to provide a solution to these problems.
According to a first aspect of the invention, there is provided a method of forming a shower base, comprising the steps of: a) providing a support mould defining an upper surface of the shower base; b) placing an upper surface layer of the shower base in the support mould; c) pouring a castable settable flowable material into the support mould onto the upper surface layer; d) positioning a castable reinforcing flexible layer in the support mould; and e) closing the support mould with a closure element whilst the castable flowable material sets.
Preferable and/or optional features of the first aspect of the invention are set forth in claims 2 to 19, inclusive.
According to a second aspect of the invention, there is provided a shower base formed using a method in accordance with the first aspect of the invention.
Preferable features of the second aspect of the invention are set forth in claim 21 and claim 22.
The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which Figure 1 is a top plan view of one embodiment of a portion of a shower tray, in accordance with the second aspect of the invention; Figure 2 is a bottom plan view of the shower tray portion shown in Figure 1; and Figure 3 is a side elevational view of the shower tray portion shown in Figure 1.
Referring to the drawings, there is shown a shower tray 10 which comprises a support surface 12 for supporting a user and having a predefined fall to a waste water outlet 14, a smoothly arcuate rising peripheral inner wall 16 which, in this case, surrounds the support surface 12, a planar or substantially planar border 18 which, in use, is marginally sloped from the horizontal towards the peripheral inner wall 16 to promote water runoff, and a peripheral outer wall 20 which depends as a continuous skirt from an outer edge of the border 18.
The shower tray 10 includes a polymer concrete main layer 22 forming a supporting body 24 of the shower tray 10, and a user-contact upper layer 26 which forms a skin on the upper surface 28 of the body 24. The upper layer 26 is in this case a preformed plastics capping sheet, and beneficially, the capping sheet may be plastics, such as acrylic. However, the upper layer 26 may be a settable gel coating, and this is beneficial since small chips or minor damage can be repaired with the tray 10 remaining in situ.
On an under surface 30 of the body 24 and/or part way through the depth of the body 24, a reinforcing layer 32 preferably comprising at least a flexible castable sheet 34 is provided. In this case, the reinforcing layer 32 is a liquid permeable continuous-filament mat 36, preferably being or including continuous-filaments of glass-fibre. Furthermore, it is preferable that the continuous-filaments are non-elastic to increase rigidity when incorporated into the shower tray.
It is important that the reinforcing sheet 34 is continuous-filament, since it must be cast to integrate with the body 24 to form a homogenous structure and thereby provide the required reinforcing strength. As such, the continuous-filaments must be sufficiently long to provide suitable gaps to allow permeation of the polymer concrete. The greater length also increases the resilience imparted to the encasing material therearound, once cast. It is considered that longitudinal extents of the continuous-filaments should be on average at least 100 mm in order to provide sufficiently large liquid-flow gaps therebetween thus enabling adequate consolidation. This allows various orientations of the continuous-filaments to be considered, such as unidirectional, interleaved or interdigitated, uniformly interwoven, or randomly interwoven. More preferably, the continuous-filaments have longitudinal extents, when ananged at least substantially straight, which match or substantially match a width or length of the support mould.
The use of continuous-filaments as defined above is highly beneficial since it enables homogenisation of the flowable and settable polymer concrete with the reinforcing layer.
Various other kinds of reinforcing material have been considered, including a short-fibre chopped-strand mat. However, a layer with non-continuous filaments, i.e. random short-fibre chopped strands, does not integrate or consolidate with the body 24 during the casting process, and thus quickly results in separation and delamination when the shower tray is put under load. Lengths of the short fibres causing such issues are on average less than 100 mm, and typically have an average length of 10 mm or less. It has been shown that, with such lengths, gaps between fibres are sufficiently small to prevent or limit permeation of the flowable casting material therethrough, thus limiting integration of the reinforcing layer and significantly reducing strength of the resulting cast product.
The reinforcing layer 32 is preferably provided on or in the body 24 continuously as one-piece so that it follows the outer wall 20, border 18, inner wall 16 and the support surface 12 up to and around the waste water outlet 14.
The under surface 30 of the shower tray 10 may also preferably be formed with foot mounts for mounting feet or legs to hold the shower tray 10 in a raised condition at the installation location. The foot mounts are preferably plates that are integrally formed with the under surface 30 of the body 24 during the casting process.
To fonTn the shower tray 10, a support mould is formed and profiled to define the upper surface of the shower tray 10. The user-contact upper layer 26, preformed to match the profile of the support mould, is placed in the support mould. If the upper layer 26 is to be a gel skin, the support mould is pre-lined with liquid gel and then allowed to at least partially set.
The support mould is then back-filled with liquid polymer concrete, covering the upwardly facing surface. If the support mould is entirely filled with the liquid polymer concrete, then the reinforcing continuous-filament flexible sheet 34 is placed on the upper surface of the liquid polymer concrete. Alternatively, if the reinforcing layer 32 is to be embedded, then the support mould is part back-filled, the continuous-filament flexible sheet 34 is placed in the support mould, and the remaining portion of the support mould is then filled with further liquid polymer concrete.
A top-hat mould closure element is then positioned on the support mould to cover and overlie the opening to the support mould. Overflow or bleed apertures are preferably included in or adjacent to the closure element to allow overflow or runoff of excess liquid polymer concrete as the closure element is pressed into place.
Typically, the closure element may define a similar profile to that of the support mould.
Alternatively, it may define a different profile. In the former case, the closure element is pressed into place, causing the reinforcing layer 32 to be substantially follow the contours of thereof and thus the profile of the support mould and the upper surface of the shower tray 10.
Once set, the closure element can be removed, finishing can take place, and the shower tray 10 can be lifted clear of the support mould.
Due to the flexible castable reinforcing layer 32, the closure element can be profiled to significantly reduce the thickness of the shower tray 10 whilst increasing its tensile strength. This provides substantial weight savings, improves safety, and reduces costs of materials. The shower tray 10 thus also becomes easier to stand in a raised condition on legs, if necessary.
Although the above method is described for producing a shower tray, it is applicable also to a shower former for providing a predetermined fall on which a waterproof flooring, such as a flexible plastics flooring, for example, Altro RTM, or tiles, can be supported. The term shower base' used herein is therefore intended to mean a shower tray and a former.
Although polymer concrete is suggested, the method is applicable for any flowable settable castable material. However, polymer concrete is particularly beneficial due to it being cost-effective and easy to work with.
The closure element may be a single one-piece pail, or maybe two or more parts which are interconnectable to close the support mould. For example, the top hat forming the outer wall, border and inner wall may be separable of the base element extending across the support surface. Closing of the support mould prevents or limits uneven casting shrinkage which occurs with a partially open moulding process.
The flexible continuous-filament reinforcing layer may be pre-cut prior to being positioned in or on the support mould, or may be a continuous sheet which is cut once it has been laid.
Although the flexible continuous-filament reinforcing layer is cast directly with the polymer concrete or other castable flowable settle material, which is beneficial in reducing cost overheads, there may be an interfacing bridging layer, such as a resin layer, interposed or substantially interposed therebetween to provide a an engagement surface for the castable flowable settable material to key onto. Such an interfacing bridging layer may, in the case of polymer concrete being the castable flowable settable material, be a polymer resin. Preferably, the interfacing bridging layer is or includes a constituent pail of the castable flowable settable material, thereby promoting bonding.
The flexible continuous-filament reinforcing layer may be pre-soaked or pre-wetted with the material of the interfacing bridging layer, prior to being placed into the support mould.
By use of the interfacing bridging layer, the continuous-filaments of the pre-soaked or pre-wetted flexible continuous-filament reinforcing layer may be made shorter than stated above. However, preferably, for this invention, it is beneficial to have a longer strand length.
Although one specific design of shower base has been described above with reference to the drawings, any castable design of shower base can be accommodated.
Furthermore, polymer concrete has been suggested as the casting material. However, any castable settable flowable material can be considered and utilised, such as blown or foamed polyester or polyurethane, or a filled or unfilled resin mix.
It is thus possible to form a shower tray having a depth of, but not limited to, 25 mm to mm. By providing a homogenous with integrated reinforcement using a continuous-filament layer, the shower base is particularly strong in tension and compression, whilst also utilising less material than has heretobefore been possible.
The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined by the appended claims.
Claims (23)
- Claims 1. A method of forming a shower base, comprising the steps of: a) providing a support mould defining an upper surface of the shower base; b) placing an upper surface layer of the shower base in the support mould; c) pouring a castable settable flowable material into the support mould onto the upper surface layer; d) positioning a castable reinforcing flexible layer in the support mould; and e) closing the support mould with a closure element whilst the castable flowable material sets.
- 2. A method as claimed in claim 1, further comprising a step f) subsequent to step d) and prior to step e) of pouring further said castable flowable material over the castable reinforcing flexible layer.
- 3. A method as claimed in claim 1 or claim 2, wherein the castable flowable material is a polymer concrete.
- 4. A method as claimed in any one of claims 1 to 3, wherein the castable reinforcing flexible layer is a continuous filament sheet.
- 5. A method as claimed in claim 4. wherein the continuous filaments of the said sheet at least include glass-fibre.
- 6. A method as claimed in claim 4 or claim 5, wherein the continuous filaments are on average at least 100 mm in length.
- 7. A method as claimed in any one of claims 4 to 6, wherein the continuous filaments, when extended substantially straight, have a longitudinal extent which extends at least a third of the way across the support mould.
- 8. A method as claimed in claim 7, wherein the continuous filaments, when extended substantially straight, have a longitudinal extent which extends at least substantially across the support mould.
- 9. A method as claimed in any one of the preceding claims, wherein the castable reinforcing flexible layer is sufficiently permeable to allow the castable flowable settable material to permeate therethrough.
- 10. A method as claimed in any one of the preceding claims, wherein the castable reinforcing flexible layer does not include chopped-strand short fibres.
- 11. A method as claimed in claim lO, wherein the short fibres have an average length of less than 100 mm or less.
- 12. A method as claimed in claim i 1, wherein the short fibres have an average length of 10 mm or less.
- 13. A method as claimed in any one of claims 1 to 12, further comprising a step g) prior to step d) of pre-wetting the castable reinforcing flexible layer.
- 14. A method as claimed in any one of claims 1 to 13, wherein the upper surface layer is preformed prior to insertion into the support mould.
- 15. A method as claimed in claim 14, wherein the preformed upper surface layer is plastics.
- 16. A method as claimed in any one of claims 1 to 13, wherein the upper surface layer is formed in the support mould.
- 17. A method as claimed in claim 16, wherein the upper surface layer is a settable gel
- 18. A method as claimed in any one of claims 1 to 17, wherein the shower base, once set in step e), forms a homogenous structure.
- 19. A method as claimed in any one of claims 1 to 18, further comprising a step h) subsequent to step d) and prior to step e) of providing spaced apart foot supports for casting in the castable flowable material.
- 20. A shower base formed using a method as claimed in any one of claims 1 to 19.
- 21. A shower base as claimed in claim 20, which is a shower former for supporting and providing a predetermined fall for a waterproof shower floor surface.
- 22. A shower base as claimed in claim 20, which is a shower tray.
- 23. A shower base substantially as hereinbefore described with reference to the accompanying drawings.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1020988.0A GB2486270A (en) | 2010-12-10 | 2010-12-10 | Improvements in or relating to a shower base |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1020988.0A GB2486270A (en) | 2010-12-10 | 2010-12-10 | Improvements in or relating to a shower base |
Publications (2)
Publication Number | Publication Date |
---|---|
GB201020988D0 GB201020988D0 (en) | 2011-01-26 |
GB2486270A true GB2486270A (en) | 2012-06-13 |
Family
ID=43567008
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB1020988.0A Withdrawn GB2486270A (en) | 2010-12-10 | 2010-12-10 | Improvements in or relating to a shower base |
Country Status (1)
Country | Link |
---|---|
GB (1) | GB2486270A (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014198990A1 (en) * | 2013-06-13 | 2014-12-18 | Novaralis S.L | Method for producing a lightweight textured shower tray and lightweight textured shower tray produced by said method |
WO2021094932A1 (en) * | 2019-11-11 | 2021-05-20 | Rademan Luke Stanton | Manhole component arrangement |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112250393A (en) * | 2020-10-19 | 2021-01-22 | 广东博智林机器人有限公司 | Hydrophobic fiber concrete, chassis structure and preparation method of chassis structure |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2087295A (en) * | 1980-11-06 | 1982-05-26 | Ebdon Michael John | Making baths, basins etc from plastics material |
WO2005011455A1 (en) * | 2003-07-25 | 2005-02-10 | Kohler Mira Limited | Composite article and method of manufacture |
GB2428567A (en) * | 2005-07-23 | 2007-02-07 | Matki Plc | Manufacture of sanitary ware |
GB2440719A (en) * | 2006-08-08 | 2008-02-13 | Aqess Co Ltd | Shower tray |
GB2469662A (en) * | 2009-04-23 | 2010-10-27 | Easability Showers Ltd | A shower tray of woven fabric in a resin polymer matrix |
-
2010
- 2010-12-10 GB GB1020988.0A patent/GB2486270A/en not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2087295A (en) * | 1980-11-06 | 1982-05-26 | Ebdon Michael John | Making baths, basins etc from plastics material |
WO2005011455A1 (en) * | 2003-07-25 | 2005-02-10 | Kohler Mira Limited | Composite article and method of manufacture |
GB2428567A (en) * | 2005-07-23 | 2007-02-07 | Matki Plc | Manufacture of sanitary ware |
GB2440719A (en) * | 2006-08-08 | 2008-02-13 | Aqess Co Ltd | Shower tray |
GB2469662A (en) * | 2009-04-23 | 2010-10-27 | Easability Showers Ltd | A shower tray of woven fabric in a resin polymer matrix |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014198990A1 (en) * | 2013-06-13 | 2014-12-18 | Novaralis S.L | Method for producing a lightweight textured shower tray and lightweight textured shower tray produced by said method |
ES2526936A1 (en) * | 2013-06-13 | 2015-01-16 | Novaralis, S.L | Method for producing a lightweight textured shower tray and lightweight textured shower tray produced by said method |
WO2021094932A1 (en) * | 2019-11-11 | 2021-05-20 | Rademan Luke Stanton | Manhole component arrangement |
Also Published As
Publication number | Publication date |
---|---|
GB201020988D0 (en) | 2011-01-26 |
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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) |