NZ314723A - Vacuum formed basin with integral waste grate - Google Patents

Description

New Zealand No. 314723 Internationa! No. PCT/ TO BE ENTERED AFTER ACCEPTANCE AND PUBLICATION Priority dates: 30.04.1996; Complete Specification Filed: 01.05.1997 Classification:^) E03C1/26; B29C51/10 Publication date: 24 September 1998 Journal No.: 1432 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION Title of Invention: Integrated basin waste Name, address and nationality of applicant(s) as in international application form: FLAIR INTERNATIONAL PRODUCTS PTY LIMITED, an Australian company of 40/132 Hassall Street, Wetherill Park, NSW 2164, Australia 314723 PATENTS FORM NO. 5 Fee No. 1 & 4: $340.00 PATENTS ACT 1953 COMPLETE SPECIFICATION INTEGRATED BASIN WASTE WE FLAIR INTERNATIONAL PRODUCTS PTY LIMITED, an Australian company of 40/132 Hassall Street, Wetherill Park, NSW 2164, AUSTRALIA hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: 1 (Followed by Page 1 A) • \ 314723 INTEGRATED BASIN WASTE The present invention relates to an integrated tub or basin waste and a method for forming same and the invention has particular application to vacuum formed tubs or basins.

For many years basins and tubs have been provided with waste apertures adjacent the lowest extremity of the basin or tub. These apertures are fitted after manufacture and usually during installation with a separate waste. The waste usually comprises a grate including an upper flange portion and a threaded tubular portion therebeneath. The waste is inserted into the basin or tub waste aperture from the inside of the basin or tub until the flange (which is of greater diameter than the waste aperture) seats onto that portion of the basin or tub immediately surrounding the waste aperture. A nut is then typically run up onto the threaded portion of the waste from below the basin or tub so that the waste is secured about the waste aperture. Plumbing may then be affixed to the threaded portion of the waste. oa-S&v Whilst the abovementioned conventional wastes have been utilised for many / ■■■ / > tf-V ' years it has always been a defect of such wastes that a certain amount of ? ?m /ater is trapped at the intersection of the flange with the basin or tub and it is ' V* 314 2 very difficult to dry or clean such area. This difficulty in cleaning and entrapment of water and suspended particles results in accumulation of grime and in many cases deterioration of the waste coating. The provision of a separate waste whether metal, plastic or otherwise is additionally relatively expensive.

It is accordingly one of the objects of the present invention to ameliorate one or more of the abovementioned disadvantages with existing wastes or at least to provide the market with an alternative.

According to the present invention there is provided a vacuum formed basin or tub having an integral waste and waste grate with a smooth unstepped transition from the interior of said basin or tub into the waste; the openings in the waste position being the result of a vacuum forming process whereby the material below the opening is initially drawn down into two or more nipples during the vacuum forming process which nipples are subsequently severed from the waste.

The present invention additionally discloses a vacuum forming process for manufacturing a basin or tub with an integrat-waste and grating comprising ,<-T the steps of: . ^ ^ •' '$97 % 31 a) Drawing the material being vacuum formed downwardly so as to form a depression at the lowest part of the interior of the basin or tub adapted to act as a plug recess; b) Further drawing the material at the bottom of said depression down into two or more separate downwardly extending nipples; c) Ensuring that the internal diameter of each nipple is of an adequately small diameter so as to prevent the passing of small objects such as rings which should not normally pass through a waste grate; d) Severing the nipples after the vacuum forming process so as to open the waste positions thereby leaving an integral grate at the waste position; the grate comprising the thermoplastic material interposed between adjacent nipp^s and not drawn down into the nipples during the nipple forming process.

One embodiment of the invention will now be described with reference to the . fAfi accompanying drawings in which: 314723 Figure I is a front to rear sectional view of a vanity basin produced in accordance with the present invention; Figure II is a partial perspective view of the waste position of a basin in accordance with the present invention prior to trimming; and Figure HI is a partial perspective view of the waste position of the basin of figure II after trimming.

Figure I discloses a vacuum formed shell 1 for a vanity basin having a bowl portion 2 a vanity top portion 3 and a splashback portion 4.

It will be observed that the basin terminates at its lowermost extremity in a waste 5 whereat the acrylic shell 1 is drawn down firstly into a circular waste conduit portion 6 and then further into smaller hollow nipples 7 only two of which are depicted in figure I. After the vacuum forming process the lower portions of the nipples 7 are severed from circular cross-section conduit portion 6 along horizontal plane 8 thereby opening the nipple portions. 314723 Typically the mould for a basin would have an aperture at the waste position and an additional cup-shaped moulding tool having a cross therein about fifteen millimetres from its upper extremity would be placed beneath the waste aperture. The cup-shaped moulding tool would be provided with holes in order that the vacuum may be drawn ihrough the cup and hence the acrylic shell drawn down through the waste position into the cup and past the cross. As the acrylic shell was drawn past the cross four small nipples would form beneath the cross within the cup.

The configuration of the waste is better viewed from figures II and III; figure II being a perspective view of the waste portion of the shell 1 in the inverted position prior to trimming of nipples 7 whereas figure III depicts the waste portion of figure II after trimming along plane 8. Nipples 7 are much truncated after the trimming operation and allow free passage of water from the basin via apertures 9 exposed after the trimming operation. It will be observed that in this example the acrylic material 10 interposed between the four adjacent nipples and not. drawn down in the nipple forming process forms a cross between apertures 9 and hence serves as a grate to prevent articles such as rings or other larger articles escaping from the basin through the waste apertures 9. Ideally the depression at the lowest part of the interior of the basin or tub adapted to receive the plug is between five and twenty millimetres in depth.

H 314723 6 It will be appreciated that by use of suitable moulding equipment the basin and waste may be formed with a very smooth transition firstly between basin 2 and circular waste conduit portion 6 and secondly circular waste conduit portion 6 and apertures 9.

Conventional waste piping may be affixed about circular waste conduit portion 6 by conventional means such as gluing, screw threads, clamping or otherwise.

It will be appreciated that alternate configurations of waste may be devised apart from those depicted "with reference to the abovementioned example and furthermore the invention is not restricted to acrylic vacuum formed basins but has application to any vacuum formed basin or tub. It is naturally intended that all such applications of the present inventive process should be covered by the present specification. 314723

Claims (8)

WHAT WE CLAIM IS:

1. A vacuum forming process for manufacturing a basin or tub with an integral waste and grating comprising the steps of: a) Drawing the material being vacuum formed downwardly so as to form a depression at the lowest part of the interior of the basin or tub adapted to act as a plug recess; b) Further drawing the material at the bottom of said depression down into two or more separate downwardly extending nipples; c) Ensuring that the internal diameter of each nipple is of an adequately small diameter so as to prevent the. passing of small objects such as rings which should not normally pass through a waste grate; d) Severing the nipples after the vacuum forming process so as to open the waste positions thereby leaving an integral grate at the waste position; the grate comprising the thermoplastic material interposed between adjacent nipples and not drawn do the nipples during the nipple forming process. 8

2. A process in accordance with claim 1 hereof wherein the material at the bottom of the depression is drawn into four downwardly extending nipples formed due to the presence of a cross-shaped mould component maintained at a position immediately below the plug recess.

3. A basin or tub having an integral waste and grate when formed by a process in accordance with any one of the preceding claims.

4. A vacuum forming process in accordance with claim 1 hereof wherein the depression at the lowest part of the interior of the basin or tub is between five millimetres and twenty millimetres in depth.

5. A vacuum forming process in accordance with claim 4 hereof wherein an externally threaded ring is glued or otherwise bonded about the exterior of the plug depression in order to accommodate traditional plumbing fittings. 9 314723

6. A vacuum forming process, substantially as described herein with reference to the accompanying drawings.

7. A basin or tub manufactured according to a process as claimed in any one of claims 4 or 5.

8. A basin or tub, substantially as described herein with reference to the accompanying drawings. Reference has been directed, in pursuance of section 16(1) of the Patents Act 1953, to patent No. 292074 by the authority of the Commissioner of Patents. FLAIR INTERNATIONAL PRODUCTS PTY LIMITED By its Attorneys TAMES & WELLS Jl ' A Hazlewood Certifying Officer