GB2486270A - Improvements in or relating to a shower base - Google Patents

Improvements in or relating to a shower base Download PDF

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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Withdrawn
Application number
GB1020988.0A
Other versions
GB201020988D0 (en
Inventor
Bill Forrington
Malcolm Baker
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.)
MARLETON GROUP Ltd
Original Assignee
MARLETON GROUP 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 MARLETON GROUP Ltd filed Critical MARLETON GROUP Ltd
Priority to GB1020988.0A priority Critical patent/GB2486270A/en
Publication of GB201020988D0 publication Critical patent/GB201020988D0/en
Publication of GB2486270A publication Critical patent/GB2486270A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47KSANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K3/00Baths; Douches; Appurtenances therefor
    • A47K3/28Showers or bathing douches
    • A47K3/40Pans or trays
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02Shaping 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
    • B29C39/10Shaping 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/769Sanitary equipment
    • B29L2031/7696Showers

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)

  1. 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. 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. 3. A method as claimed in claim 1 or claim 2, wherein the castable flowable material is a polymer concrete.
  4. 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. 5. A method as claimed in claim 4. wherein the continuous filaments of the said sheet at least include glass-fibre.
  6. 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. 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. 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. 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. 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. 11. A method as claimed in claim lO, wherein the short fibres have an average length of less than 100 mm or less.
  12. 12. A method as claimed in claim i 1, wherein the short fibres have an average length of 10 mm or less.
  13. 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. 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. 15. A method as claimed in claim 14, wherein the preformed upper surface layer is plastics.
  16. 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. 17. A method as claimed in claim 16, wherein the upper surface layer is a settable gel
  18. 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. 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. 20. A shower base formed using a method as claimed in any one of claims 1 to 19.
  21. 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. 22. A shower base as claimed in claim 20, which is a shower tray.
  23. 23. A shower base substantially as hereinbefore described with reference to the accompanying drawings.
GB1020988.0A 2010-12-10 2010-12-10 Improvements in or relating to a shower base Withdrawn GB2486270A (en)

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)

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GB201020988D0 GB201020988D0 (en) 2011-01-26
GB2486270A true GB2486270A (en) 2012-06-13

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Cited By (2)

* Cited by examiner, † Cited by third party
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)

* Cited by examiner, † Cited by third party
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)

* Cited by examiner, † Cited by third party
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

Patent Citations (5)

* Cited by examiner, † Cited by third party
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)

* Cited by examiner, † Cited by third party
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

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Publication number Publication date
GB201020988D0 (en) 2011-01-26

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