NZ780902A - Shower tray construction and method - Google Patents

Abstract

The present invention relates to a method of manufacturing a shower tray comprising: cutting a honeycomb core laminated composite sheet material to form a base panel of desired dimensions; and bonding a monolithic polymer slab to a face of the base panel, the polymer slab comprising water drainage contours. ontours.

Description

C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 SHOWER TRAY CONSTRUCTION AND METHOD Field of Invention This invention generally s to a shower tray for shower stalls. More ularly, this invention relates to a shower tray including es for ng weight and a method of producing a lightweight shower tray.

Background A shower tray is utilized in shower stalls to provide a floor structure that is shaped and adapted to collect water from the shower. A shower tray includes openings for drain devices and also provides the structural base for the shower stall.

It is common practice to manufacture shower trays by moulding or forming al into a desired shape. Examples of such materials used to produce shower trays include thermoformable plastic sheet materials and sheet moulding composite (SMC) materials in the form of glass-fibre reinforced polyester and the like. The desired shape typically includes features for containing and directing water flow to drain openings. In the case of formed plastic sheet the resulting tray comprises a shell with a hollow backside. The thermoplastic shell does not provide the desired strength required for a shower stall application and may therefore be filled with a settable mixture, which adds substantial weight to the shower tray. Alternatively, conventional prior art shower trays may utilize rib structures to provide the required th. Although such rib ures provide the necessary structural strength the result may convey a perception of reduced quality due to a hollow sound and feel.

Further, shower stalls are increasing in size and the y of available shapes. The increased size and shape are accompanied by an undesirable increase in weight of the shower tray. The increase in weight adds cost and ses difficulties during handling and installation. Moreover, an increased range in shower tray shapes and varieties necessitates a corresponding increase in moulding tools to produce them.

Accordingly, it is desirable to design and develop a shower tray and method of producing rs\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 a shower tray that reduces weight while still conveying the desired look and feel.

Summary According to the present invention a shower tray comprises a honeycomb core laminated composite base panel supporting a monolithic polymer slab having water drainage contours.

In one form of the invention the honeycomb core ted composite material comprises an aluminium core cellular structure ched between aluminium facing sheets. In one ular embodiment the base panel has an l thickness of approximately 10mm.

The polymer slab preferably comprises a polyurethane, polystyrene, PVC or polypropylene material with a density in the range from 85 kg/m3 to 250kg/m3. The polymer slab is preferably bonded to a face surface of the base panel and has a uniform thickness in the range from 15mm to 30mm before. The polymer slab may be bonded to the base panel and subsequently machined to form the water drainage contours. In an alternative approach, water drainage contours may be formed in the polymer slab before the polymer slab is bonded to the base panel.

The shower tray may also be formed with a water drainage outlet aperture extending through the polymer slab and base panel at a location corresponding to the m point of the water drainage rs. In an embodiment, edge walls may be affixed around the perimeter of the base panel and polymer slab. ing to the present invention there is also provided a method of manufacturing a shower tray comprising: cutting a honeycomb core laminated composite sheet material to form a base panel of desired dimensions; bonding a monolithic polymer slab to a face of the base panel; machining the polymer slab to form water drainage contours; and forming a water drainage outlet aperture extending through the polymer slab and base panel at a location ponding to a minimum point of the water drainage rs.

In another embodiment, the present invention further provides a method of manufacturing a C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 shower tray comprising: g a omb core laminated composite sheet material to form a base panel of desired dimensions; and bonding a monolithic polymer slab to a face of the base panel, the polymer slab comprising water drainage contours. The method may further comprise forming a water drainage outlet aperture extending through the polymer slab and base panel at a location ponding to a minimum point of the water drainage contours.

In another embodiment the present ion es a fixture for use when the shower tray of the invention is being installed. The fixture is adapted to be secured to the base panel of the shower tray and abut a stud wall when the shower tray has been oned/installed at a desired position. The fixture will be described in more detail below.

In another ment, the present invention provides a corner sleeve component for use when the shower tray of the invention is being installed. The corner sleeve component would be used in conjunction with (pairs of) the fixture referenced above. The corner sleeve component will also be described in more detail below. r aspects, features and advantages of the present invention will be apparent to those of ordinary skill in the art from the accompanying description and drawings.

Brief Description of Drawings In order that the invention may be more easily understood, the following detailed description is provided including description of several embodiments, presented by way of e only, and with reference to the accompanying drawings in which: Figure 1 is a perspective view of a shower tray according to an embodiment of the invention, shown in central cross-section; Figure 2A is a perspective view of a shower tray base panel cut to specified dimensions; Figure 2B diagrammatically illustrates a laminated honeycomb core sheet material structure; Figure 3 is a perspective view of the shower tray base panel with a monolithic rs\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 polymer slab bonded thereto; Figure 4 is a perspective view of the shower tray base panel and polymer slab with water drainage contours; Figure 5 is a ctive view of the shower tray base panel with polymer slab with partial application of perimeter edge walls; Figure 6 is a perspective view of the shower tray base panel with polymer slab with edge walls applied; Figures 7 and 8 are two different perspective views of the shower tray complete with water drainage outlet aperture; Figure 9 shows the complete shower tray structure of Figure 8 in central crosssection Figure 10 is a front elevation view of the sectioned shower tray structure of Figure Figure 11 is illustrates another shower tray constructed according to an ment of the invention having a different shape and drainage contours, seen in plan, front and side elevations; Figure 12 is a flow chart diagram illustrating a ce of operations for manufacture and subsequent installation of a shower tray ing to embodiments of the invention; Figures 13 and 14 are two different perspective views of the shower tray; and Figure 15 is a sectional view of a shower tray installed in relation to various components.

Detailed Description A central cross-section through a shower tray 10 according to an embodiment of the invention is seen in perspective view in Figure 1. The shower tray 10 comprises generally a base panel 20 supporting thereon a polymer slab 30 with water drainage contours 32 and a corresponding water drainage outlet aperture 36 that s through the base panel. The perimeter of the shower tray is fitted with edge walls 40.

Various s and the accompanying description relate to machining of a polymer slab to produce water drainage rs and a water drainage outlet after bonding of the polymer C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 slab to the base panel. However, it will be iated that in a variation the polymer slab may already e water drainage contours and/or a water drainage outlet before bonding of the polymer slab to the base panel, i.e., the polymer slab may be provided with one or both of these es so that reduced or no machining of the polymer slab is ed. This may simplify production and installation of the shower tray.

A shower tray needs to be able to support the weight of a person during use, and therefore es certain structural support characteristics, either provided by the tray itself or by the building or vehicle in which the tray is installed. In embodiments of the present ion structural support characteristics of the shower tray 10 are ed by the base panel 20 which ses a laminated honeycomb core sheet material. ted honeycomb core sheet materials have a number of advantageous properties for use in this application including high stiffness and support strength perpendicular to the sheet extent and relative to the material weight. For example, aluminium honeycomb core laminate produces one of the highest strength/weight ratios of any structural material.

The general structure of a honeycomb core laminate material is shown diagrammatically in Figure 2B comprising a two-dimensional web forming a cellular core structure 24 that is sandwiched between two sheet material layers 22. The sheet material layers 22 are securely bonded to the cellular core structure, and since the cell walls are dicular to the sheets 22 the ed laminate material is very stiff. Moreover, since the cells of the honeycomb core are air filled (or in some cases filled with lightweight foam) the composite material is very light for its strength. ties of the honeycomb core laminate material may depend on an number of factors ing the material, sheet thickness, depth and cell size of the honeycomb core structure, and the material and thickness of the laminated facing sheets.

In one form of the invention the honeycomb core laminate material comprises aluminium foil honeycomb core with laminated ium facing sheets. In one form the aluminium foil forming the honeycomb core is 0.076mm thick and the cellular structure has a cell size (~cell-diameter) of approximately 10mm. The facing sheets may comprise 1mm thick aluminium, for example. For a honeycomb core laminate composite material of this construction, for the purposes of the present application it has been found that an overall C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 material ess (including facing sheets) of approximately 10mm provides appropriate strength and stiffness for the shower tray base panel.

Examples of honeycomb core laminate composite materials that have generally been found to be suitable to the present application include: 1. Fibreglass fibre facing 1mm + aluminium honeycomb core + glass fibre facing 2. Aluminium Skin + ium honeycomb core + aluminium skin. 3. Glass fibre facing + aluminium skin + aluminium honeycomb core + aluminium skin + glass fiber facing.

In each case a cell size of 10mm and a foil ribbon gauge of 0.076mm have been found to be suitable, although it will be recognised that various cell sizes and foil thicknesses may alternatively be employed to achieve the desired strength. er, different thicknesses of facing sheet materials and overall te thickness may also be used to e the desired properties. In the case of the third al structure outlined above, an ium skin thickness of 1mm on each side, together with bonded fibreglass facing sheets on each side (0.25mm+0.25mm) provides additional strength over the fully aluminium structure, but is substantially more expensive.

Commercially ble aluminium honeycomb core products that have been found to be le for application include PCGA-XR2 3003 commercial grade aluminium honeycomb, which is a lightweight core material made from 3003 aluminium alloy foil offering excellent strength and corrosion resistance for industrial applications at low cost. The R2 3003 honeycomb is available in four forms: unexpanded blocks, unexpanded slices, untrimmed expanded sheets and cut to size expanded sheets.

Other honeycomb core structures that may be employed instead of the above described ium foil matrix include aramid fibre paper (Nomex), glass-reinforced c (also known as fiberglass), carbon fiber reinforced plastic, Nomex paper reinforced plastic.

Carbon-core plastic honeycomb sheets are made out of polypropylene and come in an open cell configuration or with a layer of non-woven polyester scrim for a one hundred percent C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 bonding surface. Any of the honeycomb core cellular ures may include cells filled with foam which has the benefit of providing a greater skin bonding area. Foam densities in the range of 40kg/m3 to 500kg/m3 are generally suitable, and examples of two-component rigid foams are commercially available from Fibremax Composites.

Referring again to Figure 1, a slab layer 30 of polymer material is affixed to the top surface of the base panel 20. The slab layer 30 may comprise polyurethane, polystyrene, PVC or polypropylene material, for example, with a thickness lly in the range from 15mm to 30mm and with a density generally in the range from 85 kg/m3 to 250kg/m3. In ments of the invention as described below, the slab layer 30 may be cut to the same size as the base panel and then bonded to the top surface f using a suitable adhesive. After the slab layer 30 is bonded to the base panel 20 the top of the slab layer is machined to provide water drainage rs 32 ing to a desired uration. A water drainage outlet aperture 36 is also machined through the polymer slab layer 30 and base panel 20 in a location as determined by the water drainage contours 32 (i.e., at the location where the machined r is lowest).

Before installation the shower tray 10 may be fitted with edge walls 40 around the perimeter thereof, if necessary for the particular application – depending on the intended installation the edge walls may not extend around the entire perimeter, or may have different heights on different sides of the tray.

A shower base drainage outlet fitting (not shown in the gs) would also be installed in the outlet aperture for coupling to wastewater plumbing.

Figures 2 to 7 illustrate the primary operations involved in manufacture of a shower tray according to embodiments of the invention. Figure 12 also shows a flow chart diagram of the ce of process operations 70 that will be explained below.

The manufacturing process 70 begins with operation 72 wherein a suitable honeycomb core laminate sheet material (discussed above) is cut to specified size for a particular shower tray installation. The composite material cut to specified size comprises the base panel 20 (Figure C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 2). Common rd shower base sizes in Australia are (measurements in mm): 900 by 900, 1000 by 1000, 900 by 1200, 900 by 1660. Embodiments of the present invention cater for any of the various shower base sizes mentioned above and, due to the unique manufacturing process, can odate most non-standard size requirements as well.

Once the base panel 20 has been cut to size, a monolithic slab 30 (Figure 3) of polymer material is bonded to the top surface of the base panel using adhesive (process operation 74).

The slab layer 30 may be cut to size matching the base panel 20 and then affixed thereto, or an oversized layer of material may be first affixed to the base panel and then d to match. As mentioned above, the al of the slab layer 30 may be selected from several different candidates, and lly will have a thickness in the range of 15mm to 30mm, depending on the size of the shower tray being constructed. A larger shower tray may use a thicker slab layer than a smaller shower tray in order to allow for machining of water drainage rs according to recommended fall ratios, as sed below.

At operation 76 the top of the monolithic polymer slab layer 30 is machined to form a d water drainage contour surface 32 (Figure 4). ing to the Building Code of Australia (BCA) and Australian Standard AS3740 the recommended ratio of fall within s (i.e., the slope of the shower tray floor surface) is between 1:60 and 1:80. In the Figures the drainage contour is shown sloping from near each edge toward the centre, although other contours are also possible (see Figure 11, for example). The fall ratios shown in the Figures are not to scale and may be rated for visual distinction.

Machining the water drainage contours 32 into the polymer slab layer 30 may be accomplished using a CNC (Computer Numerical Control) or other automated machining apparatus suitable for milling plastics material such as polyurethane and the like. The automated machining apparatus is preferably programmed or controlled to form the desired contour surface based on a CAD or other digital model, as understood by those skilled in the art. Once the drainage contours are formed the same or different apparatus may be used to create the drainage outlet aperture 36, typically at the lowest point of the contoured surface 32 (operation 78). rs\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 The next stage of manufacture (operation 80) involves installing edge walls 40 around the perimeter of the base panel and machined slab structure, preferably being affixed using a waterproof adhesive. The edge walls 40 may se a polymer material such as PVC or composite such as SMC or BMC and typically have dimensions of approximately 6-10mm thickness and around 65mm in total height (e.g., projecting above the edge of the slab layer by several centimetres). Figures 5 and 6 illustrate lation of the edge walls 40 (the edge walls 40 shown in the s are not to scale). Different height edge walls may be installed on ent edges of the shower tray (or be machined after installation) according to the configuration intended for installation and ingress/egress access to the shower stall.

The final operation (Figure 12, step 82) before the shower tray 10 is ready for installation is fitting a drainage outlet fixture (not shown in the drawings) to the to the drainage outlet aperture 36. The drainage outlet fixture is affixed and sealed in the outlet aperture and es a drainage pipe coupling or the like for connection to a wastewater plumbing system. Once manufacture of the shower tray 10 is complete it may be installed in the intended location (operation 84). For ease of installation the structure of the shower tray 10 and the als employed in its manufacture permit tiles to be d directly onto the contoured water drainage surface 32, although waterproofing measures may first be taken particularly around the edges of the shower tray as required by regulation or the like.

Alternatively, a polymer sheet material such as a PVC or vinyl film may be applied to finish the shower tray e d of tiles.

Figure 11 illustrates in plan and orthogonal central sections a shower tray 10 according to an embodiment of the present invention having a rectangular shape and a different water drainage contour than previously described. In this instance the water drainage contour is configured with surfaces sloping to a channel 35 located toward one end of the shower tray, n the drainage outlet aperture 36 is centrally located in the channel. Other tray shapes and drainage contour configurations are of course also possible.

In embodiments of the ion the shower tray comprises one or more edge walls 40 around its perimeter. Installation of this kind of shower tray will include a step of cutting parts of wall studs to receive/accommodate the edge walls when the shower tray is located C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 in the desired position. The intention is for the edge walls to be fully recessed in the wall studs so that the edge walls do not impede subsequent positioning of (waterproof) plasterboard sheeting and attachment of the wall sheets to the wall studs. Accordingly, the wall studs are cut to accommodate the height (usually around 65mm) and thickness (usually ) of relevant edge walls. Cutting of walls studs to achieve this is common practice but requires careful measurement and execution.

In an ment of the invention the shower tray can be installed without needing to cut wall studs to odate an edge wall. In this embodiment a perimeter section of the shower tray may be abutted to a wall stud using a lly designed fixture that spans the perimeter section and extends up the stud wall. The fixture is adapted to be secured to the base panel of the shower tray. The fixture is also adapted to abut with wall studs present along the perimeter section such that the fixture does not unduly interfere with subsequent positioning and attachment of plasterboard sheeting to a wall stud.

In an embodiment the fixture comprises a tab (a short tion) that is sized and shaped for insertion into, and friction fit with, the base panel. More specifically, into and with the honeycomb core of the base panel. Insertion of the tab is likely to cause some localised displacement/crumpling of the omb core. However, insertion of the tab should not cause any delamination of the base panel. As noted above, the base panel may have a thickness of approximately 10mm. In this case the critical dimension of the tab to allow it to be inserted into the core of the base panel will be slightly less than this thickness.

The fixture will also e a projection that allows it to abut wall studs. To avoid interfering with a wall sheet when subsequently applied, the projection must be suitably thin so that it does not unduly protrude from the surface of the wall stud when positioned adjacent to it. Typically, the relevant dimension of the projection is 1-2mm. The height of the projection (in the direction extending up the wall stud) may be approximately 65mm. The length of the fixture will vary depending upon the perimeter n of the base panel of the shower tray to which it is to be attached.

The fixture is intended to e a water r and may be waterproofed accordingly C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 where it is joined to other components, such as the polymer slab.

Although not essential, the fixture may be secured to the base panel and/or wall studs using wall stud using a suitable adhesive.

The fixture should be suitably rigid, water resistant and corrosion resistant. Preferably it is formed of a material of low density. Typically, it is formed of aluminium, for e by ion. For simplicity, the e is usually produced as a unitary piece.

Where fixtures of the type described are provided on adjacent perimeter sections, the edges of the fixtures will come together at a corner. To provide improved rigidity and strength at this corner, a corner sleeve ent may be used. This component is adapted to slide over and provide a friction fit with respect to respective leading edges of fixtures as they come er at the corner. The corner sleeve component may be adapted to receive the edges of fixtures that extend at right angles to each other, or at other angles as may be desired.

When the corner sleeve portion has been attached to the edges of respective fixtures, waterproofing may be applied.

The corner sleeve n should provide le rigidity. It should also be water resistant and corrosion resistant. Preferably it is formed of a low-density material. It may be formed of aluminium, for example by ion. Desirably, the corner sleeve portion should be sized (thickness) so as not to interfere with placement and ment of wall sheets, as described above with respect to the fixture.

The use of fixtures and corner sleeve components are lightweight and may be flat packed.

This may provide advantages with respect to storage, ing for supply and transportation.

Figure 13 shows a shower tray 10 provided with two fixtures 41extending along two orthogonal perimeter sections A, A’ of the shower tray 10. Each fixture 41 comprises a tab 42 that is sized and shaped for insertion into, and friction fit with, the honeycomb core of base panel 20. For the purposes of illustration in the embodiment shown, the fixtures 41 C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower pecification v2(22012214.1).docx-29/09/2021 extend beyond the perimeter sections A, A’of the shower tray 10. In practice the fixtures 41 would be cut to appropriate length before fitting to the shower tray 10. Each fixture 41 includes a thin, elongate projection 43 that allows it to abut to wall studs (not shown).

Figure 13 also shows a corner sleeve ent 44 shaped to receive the edges of es 41. The component 44 includes narrow slots that are sized to slidably receive and retain the edges of fixtures 44 by on fit. The component is typically sized so that the lower end of the component 44 sits flush with polymer slab 30 and the upper end of the ent 44 aligns with the upper edge of the projection 43 of the fixtures 41.

Figure 14 is an exploded view g the rear side of the component 44 and fixtures 41.

Figure 15 shows installation of a shower tray 10 with respect to support beams 45, stud wall 46 and waterproof plasterboard 47. The base panel 20 is bonded to respective support beams 45 using a suitable adhesive. Fixture 41 is secured to the base panel 20 via tab 42 inserted into the honeycomb core 24 of the base panel 20 between sheet material layers 22. When the shower tray 10 is in the desired position the projection 43 of the fixture 41 abuts and extends up the stud wall 46. The projection 43 is sufficiently thin so that it does not impede subsequent fitting of waterproof plasterboard 47. The figure also shows corner sleeve component 44. For the purposes of illustration, the component 44 is depicted as engaging with only one fixture 41. The figure also shows polymer slab 30. At various stages of lation waterproofing would be applied, and one skilled in the art would be very familiar with this requirement and how to ent waterproofing.

The invention has been described by way of non-limiting example only and many modifications and variations may be made thereto without ing from the spirit and scope of the invention.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour C:\Users\Apirie\AppData\Roaming\iManage\Work\Recent\35566895AU Shower tray\Specification v2(22012214.1).docx-29/09/2021 to which this specification relates.

Throughout this ication and the claims which follow, unless the context requires ise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Document3-27/09/2021 ABSTRACT The present ion relates to a method of manufacturing a shower tray comprising: cutting a honeycomb core laminated composite sheet material to form a base panel of desired ions; and bonding a monolithic polymer slab to a face of the base panel, the polymer slab comprising water drainage contours.

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Claims (7)

Claims

1. A method of manufacturing a shower tray comprising: cutting a honeycomb core ted composite sheet al to form a base panel of desired dimensions; and 5 bonding a monolithic polymer slab to a face of the base panel, the polymer slab comprising water ge contours.

2. The method of claim 1, further comprising forming a water drainage outlet aperture ing through the polymer slab and base panel at a location corresponding to a minimum 10 point of the water drainage contours.

3. A method of manufacturing a shower tray comprising: cutting a honeycomb core laminated composite sheet material to form a base panel of desired dimensions; 15 bonding a monolithic polymer slab to a face of the base panel; machining the polymer slab to form water ge contours; and forming a water drainage outlet aperture extending h the polymer slab and base panel at a location corresponding to a minimum point of the water ge contours. 20

4. A shower tray comprising a honeycomb core laminated composite base panel supporting a monolithic polymer slab comprising water drainage contours.

5. A shower tray manufactured ing to the method of claim 1, 2 or 3. 25

6. A shower tray according to claim 4 or 5 wherein the honeycomb core laminated composite material comprises an aluminium core cellular structure sandwiched n aluminium facing sheets.

7. A shower tray according to claim 6, wherein the honeycomb core laminated 30 composite material includes a glass fibre facing sheet in addition to or in substitution for one or both of the respective aluminium facing sheets C:\Users\Apirie\AppData\Local\Microsoft\Windows\INetCache\Content.Outlook\NJSH38NS\Specification v2(22012214.1).docx-