WO1997005996A1

WO1997005996A1 - Method for reflanging a vessel, mouldings and resultant vessel

Info

Publication number: WO1997005996A1
Application number: PCT/AU1996/000508
Authority: WO
Inventors: Stanley George Herbert
Original assignee: Stanley George Herbert
Priority date: 1995-08-10
Filing date: 1996-08-12
Publication date: 1997-02-20
Also published as: AUPN473795A0; GB2319983A; GB9802828D0

Abstract

A method for reflanging a broadly flanged vessel such as a bath (11). The method includes firstly cutting off the expansive flange portion (19) of the bath (11) so as to retain a uniform peripheral edge (17). A pre-formed moulding (21) having a complementary inner engaging portion (23) and an outer contoured portion (25) is then located in apposition with the edge (17). The method includes fixedly engaging the moulding (21) and the edge (17) in such apposition. The moulding (21) and the edge (17) have keyways (34 and 20), previously formed therein, which are keyed with a keying filler (42). The method then includes moulding the moulding (21) and the edge (17) with a bonding filler (44) to form a continuous and contoured outer surface extending from inside the bath (11) to the outer periphery of the outer contoured portion (25). Finally, the outer surface is smoothed and coated to finish reflanging of the bath (11). Various alternative mouldings and flanging arrangements are also described together with jig arrangements for forming the mouldings from extrusions.

Description

"Method for Reflanging a Vessel, Mouldings and Resultant Vessel"

The present invention relates to a method for reflanging a broadly flanged vessel, a vessel so reflanged, and a moulding for use in such method. The invention has particular utility in the modification and refashioning of old style baths, particularly those made of cast iron that were fashionable and popular up until the middle of this century.

Old style baths mass produced earlier this century were characterised by having a sunken portion with outwardly flared walls and of elongated shape, where one end of the bath was arcuately contoured in a concave manner with respect to the inside of the bath, and the opposite end at which the tap and spout fittings were usually disposed was substantially squared with concavely formed corners. The early form of these types of bath were cast from iron with a rolled edge, which formed a highly convexly curved outer flange around the entire periphery of the bath. This flange was comparatively narrow, having an outer projecting extent of approximately 7 to 10 cms, and was substantially constant around the entire periphery of the bath.

With the advance of time, these flanges became less pronounced in their convexity and increasingly broad. These changes came about principally for utilitarian purposes and as a result of the trend away from free standing alone bath tubs to built-in baths. With the latter, the outer periphery of the flange started adopting more of a rectangular shape in plan, whereby an outer side wall for the bath was separately formed which could be capped by the broad flange.

As a result of these modern developments, the old style cast iron bath with the narrow rolled edge effectively became obsolete.

With the passage of time and the introduction of new fabricating materials, such as stainless steel, plastic and fibreglass, the broad flanged cast iron baths similarly became obsolete. ln recent times, with changes in fashion and new found respect for old time craftsmanship, cast iron baths have been making a return. However, with respect to the exceedingly high costs associated with the manufacture of cast iron baths in terms of today's technology, and the value placed on genuine antiquity, there is a growing industry in relocating and reselling the genuine original style cast iron bath as opposed to manufacturing it as new. Unfortunately, due to the antiquity of the old style baths, the rolled edge form has become exceedingly scarce compared with the broader flange type. Indeed, the broader flange type is quite common, however due to the broad rectangular flange provided with such baths, these baths are only suitable for being built in, as opposed to being free standing, and therefore they have not featured in the revival of the old time cast iron baths to date.

Notwithstanding the unpopularity of the broader flange type bath, the sunken portion of these baths is substantially identical to the sunken portion of the narrow rolled edge bath. Consequently, it is an object of the present invention to provide for reflanging a broadly flanged bath, and indeed any form of broadly flanged vessel, to form a narrow flanged vessel, the vessel so re-flanged, and mouldings to achieve this reflanging.

In accordance with a first aspect of the present invention, there is provided a method for reflanging a broadly flanged vessel including:

cutting off the expansive flange portion of the broadly flanged vessel so as to retain a uniform peripheral edge;

locating a pre-formed moulding having a complementary inner engaging portion and an outer contoured portion, in apposition with said edge;

fixedly engaging said moulding and said edge in said apposition; moulding said moulding and said edge with a bonding filler to form a continuous and contoured outer surface extending from inside the vessel to the outer periphery of said outer contoured portion;

smoothing and coating said outer surface to finish reflanging the vessel.

Preferably, said method includes roughing the surface of said edge to facilitate keying of said bonding filler thereto.

Preferably, said inner engaging portion includes a recess to define an inner flange, and the locating of said pre-formed moulding includes overlapping said inner flange with said edge.

Preferably, said inner engaging portion is formed with a keyway within said recess to confront said edge when disposed in apposition thereto to facilitate keying of said filler thereto.

Preferably, the fixed engaging of said moulding and said edge includes: temporarily clamping said moulding and said edge together; drilling a series of holes transversely through the overlapping portions of said inner flange and said edge at spaced apart locations along the entire circumferential extent of said edge; tapping each of said holes to cut a screw thread therein; and screwing a threaded fastener through each of said holes to permanently fix said moulding and said edge in said apposition.

Preferably, said threaded fastener includes a bolt and nut arrangement, and the fixed engaging of said moulding and said edge includes coating a said bolt with a bonding composition prior to screwing the same through a said hole and with a said nut to promote bonding and affixture to the side of the hole and threaded engagement with said nut. Preferably, said method includes shearing protruding portions of said nut and bolt arrangement after said bonding and affixture.

Preferably, the method includes cutting a keyway into the end of said edge prior to locating said moulding in apposition thereto.

Preferably, the fixed engaging of said moulding and said edge includes: temporarily clamping said moulding and said edge together; introducing a fluid keying filler into the interface between said edge and said moulding to occupy said holes; and allowing said keying filler to set.

Preferably, the moulding keyway and the edge keyway are disposed oppositely each other when said moulding and said edge are brought into apposition with each other.

Preferably, said edge comprises a marginal peripheral lip of substantially constant lateral extent and corresponding shape to the outline of the sunken portion of the vessel.

Preferably, said recess is disposed on the intended upper side of said moulding and defines a step having a riser portion with a transverse extent commensurate to the thickness of said lip, and the locating of said pre-formed moulding includes locating said inner flange in apposition to the underside of said lip and said riser adjacent to the outer periphery of said lip, so that the upper surface of said outer contoured portion of said moulding is substantially coextensive with the upper surface of said lip.

Altematively, said recess may be disposed on the intended underside of said moulding and defines a step having a riser portion with a transverse extent commensurate to the thickness of said lip, and the locating of said pre-formed moulding includes locating said inner flange in apposition to the upper side of said lip and said riser portion adjacent to the outer periphery of said lip, so that the upper surface of said outer contoured portion of said moulding is substantially contiguous and coextensive with the inner surface of the sunken portion of said vessel.

Alternatively still, said edge comprises the top of the vessel wall below the expansive flange portion of the vessel.

Preferably, said recess is disposed on the intended inner side of said moulding and defines a step having a riser portion with a transverse extent commensurate to the thickness of said edge, and the locating of said pre-formed moulding includes locating said inner flange in apposition to the outer side of said edge and said riser adjacent to the outer periphery of said edge, so that the upper surface of said outer contoured portion of said moulding is substantially contiguous and coextensive with the inner surface of the sunken portion of said vessel.

Preferably, the method includes forming said pre-formed moulding by extrusion to the requisite cross-section configuration, cutting a series of spaced apart slots orthogonally along said inner engaging portion at regions thereof which are to be arcuately disposed relative to said edge when brought into apposition therewith, and bending said moulding along said regions to adopt the requisite curvature for apposed relationship with said edge.

Preferably, said moulding is initially formed in at least two discrete sections and pursuant to said bending of each section, said sections are welded together to form a unitary pre-formed moulding for use in the remainder of the method.

In accordance with another aspect of the invention, there is provided a reflanged vessel formed in accordance with the method defined in the preceding aspect of the invention. ln accordance with a further aspect of the present invention, there is provided a moulding for reflanging a broadly flanged vessel including:

an inner engaging portion for engaging a peripheral edge of said vessel and an outer contoured portion,

said inner engaging portion having a recess to define an inner flange and a step having a riser portion with a transverse extent commensurate to the thickness of the peripheral edge.

Preferably, said inner flange projects outwardly from said step a distance commensurate to the outer projection of the edge.

Preferably, said outer contoured portion is convexly shaped.

Preferably, said step is disposed intermediate of and contiguous with said inner engaging portion and said outer contoured portion, such that said recess is disposed on the intended upper side of said moulding.

Alternatively, said step may be disposed oppositely of said outer contoured portion such that said recess is disposed on the intended underside of said moulding.

Alternatively still, said step may be disposed intermediate of and contiguous with said inner engaging portion and said outer contoured portion, such that said recess is disposed on the intended inner side of said moulding.

The invention will be better understood in the light of the following description of four principal embodiments thereof and several secondary embodiments. The description is made with reference to the accompanying drawings, wherein:-

Figure 1 is a perspective top view of a broadly flanged bath; Figure 2 is a similar view to figure 1 but showing the expansive flange portion of the bath cut off and separated from the bath;

Figure 3 is a similar perspective view to figures 1 and 2 but showing the provision of an underside moulding in accordance with the first principal embodiment of the invention for locating around the peripheral lip of the remaining bath;

Figure 4 is a similar perspective view to figures 1 to 3 showing the underside moulding fixedly engaged insitu with the peripheral lip of the bath;

Figure 5 is a cross-sectional view showing the relative spatial relationship between the underside moulding and the peripheral lip in the finished form of the flange;

Figure 6 is a top perspective view showing a re-flanged bath provided with an upper side moulding in accordance with the second principal embodiment;

Figure 7 is a cross-sectional view showing the spatial arrangement of the upper side moulding and the peripheral lip of the bath in the finished arrangement;

Figure 8 is a cross-sectional view showing the spatial arrangement of an upper side moulding in accordance with the third principal embodiment and the peripheral lip of the bath in the finished arrangement;

Figure 9 is a side elevation of a jig for bending the moulding sections using the extrusion method of preforming; Figure 10 is a plan view of the jig of figure 9 showing a moulding section being bent;

Figure 11 is a fragmentary side elevation showing the bending arm and jig during a bending operation;

Figure 12 is a plan view of a welding jig for adjoining the bent moulding sections; and

Figure 13 is a side elevation of figure 12.

The principal embodiments of the invention are directed towards methods for reflanging a broadly flanged bath, and other secondary embodiments of the invention are directed towards a reflanged bath so formed and mouldings used in the aforementioned methods, all of which are described in conjunction with the principal embodiment.

The first principal embodiment is specifically directed towards the conversion of a broadly flanged cast iron bath, as shown in figure 1 of the drawings to a narrow flanged bath using an underside moulding.

The broadly flanged bath 11 essentially comprises a sunken portion 13 and an expansive flange portion 15. The bath is elongated, and has the sunken portion arcuately curved concavely at one end, and squared off with concave corners at the other end. Accordingly, the sunken portion has a characteristic outline in plan, which is followed by the flange portion 15.

The outer periphery of the expansive flange portion 15 is substantially rectangular and so the flange portion is more broadly expansive at the corners of the flanged portion than at the sides. Nonetheless, there is sufficient expansiveness of the flanged portion all around the outline of the sunken portion 13 to define a uniformly shaped marginal portion of the flange within a distance of at least 45 to 50 mm of the lip from the outline of the sunken portion.

The method for reflanging the bath 11 firstly involves roughening the entire surface of the bath to facilitate keying of fillers and coatings to the bath. This roughening is conveniently achieved by sand blasting and is particularly concentrated around the inner uniform marginal portion of the expansive flange.

The expansive flange portion of the bath is then cut off with a suitable cutting machine such as an angle grinder, at a fixed distance from the outline of the sunken portion of the bar so as to retain a uniform peripheral edge forming a marginal peripheral lip 17 of substantially constant lateral extent and corresponding shape to the outline of the sunken portion of the vessel. This lip 17 constitutes the marginal portion of the expansive flange portion 15 which is uniform around the entire outline of the sunken portion of the bath. The remaining rectangular flange portion 19 of the expansive flange portion which is cut off is then discarded.

It is not important whether the sand blasting step is performed prior to cutting off the expansive flange portion or after and so other embodiments may involve the latter sequence.

Next, a keyway 20 is cut into the end of the peripheral lip 17, around the entire circumference of the bath edge, facing outwardly.

A preformed underside moulding 21 is located underneath the bath as shown in figure 3 and is then brought into apposition with the lip 17.

The moulding is similarly formed of metal and has a complementary inner engaging portion 23 and an outer contoured portion 25. ln the specific embodiment of the underside moulding 21 , the inner engaging portion 23 is provided with a recess 27 on its upper surface which defines an inner flange 29 and a step 31 having a riser portion 33. The step 31 is disposed intermediate the outer contoured portion 25 and the inner engaging portion 23, and is contiguous with the upper surface 25a of the outer contoured portion and the upper surface of the inner flange 29.

A keyway 34 is formed along the riser portion 33, projecting inwardly in substantially parallel relationship to the inner flange, and extending along the entire circumference of the step 31.

The upper surface 25a of the outer contoured portion is convexly contoured, and projects outwardly laterally of the longitudinal extent of the moulding and forms a rolled outer edge 35, the distal end of which is depressed relative to the remainder of the underside 37 of the moulding.

The riser portion 33 has a transverse extent commensurate to the thickness of the peripheral lip 17, as best shown in figure 5 of the drawings, and further, is disposed obliquely relative to the normal, so as to be obtuse relative to the plane of the inner flange 29. The inner flange 29 projects outwardly from the step a distance commensurate to the outer projection of the lip 17 so that when the inner flange is brought into apposition with the underside of the lip, the end of the lip is disposed adjacent to the riser portion 33 of the step 31 defining a small cavity 39 which is triangular in section between the end of the lip and the riser portion. In this cavity 39 the moulding keyway 34 and the lip keyway 20 are disposed in substantially coplanar confronting opposition to each other.

The moulding 21 is temporarily clamped in apposition to the lip 17 by an appropriate clamping mechanism such as a G-clamp or the like and then a series of holes 41 are drilled transversely through the overlapping portions of the inner flange 29 and the lip 17 at regular spaced apart locations along the entire longitudinal extent of the lip. As shown in figure 4 of the drawings, the holes are spaced approximately 15 to 20 cms apart, and as shown in figure 5 of the drawings are intended to accommodate corresponding threaded fasteners 43 in the form of bolt and nut arrangements, one to each hole.

In order to threadedly receive the bolt and nut arrangements, each hole is tapped to cut a female screw thread therein.

The bolt of each bolt and nut arrangement is then coated with a suitable bonding composition, such as that sold under the trade mark "LOC-TITE" and is screwed through the corresponding hole and fastened with a nut to promote bonding and affixture of the bolt to the side of the hole and threaded engagement with the female screw thread of the hole.

The bonding composition is allowed to set, and while setting, the bath is levelled and a fluid keying filler 42 in the form of a molten metal such as lead is poured into the cavity to fill the keyways 20 and 34 and key the moulding 21 to the peripheral lip 17 on setting.

The keying filler 42 is allowed to set. After both the keying filler and the bonding composition around the threaded fastener 43 have set, the protruding portions of each nut and bolt arrangement are sheared off. A bonding filler 44 in the form of plastic putty, such as is sold under the trade mark "PLASTIBOND", is then pressed over the keying filler 42 and the remainder of the small cavity 39 and moulded over the moulding 21 and lip 17 to form a continuous and contoured outer surface. The bonding filler 44 extends from the inside of the top of the wall of the sunken portion 13 of the bath, over to the outer periphery of the rolled edge 35 to cover the opposing ends of the fastener, completely obscuring the same, and the keying filler and cavity, then along the underside of the moulding, and into any residual gap disposed between the end of the inner flange 29 and the underside of the lip 17. After the moulding has been completed and is cured, the outer surface of the re¬ formed flange is then smoothed by rubbing down initially with an appropriate abrasive such as 120 grid sandpaper and then finished with a finer polishing abrasive such as 350 grid sandpaper to achieve a smooth and contiguous outer surface of the sunken portion and flange.

The embodied method then involves applying a prime coat of enamel to the entire bath which is allowed to air dry and then a finishing coat of enamel which is dried by baking in an oven at a temperature set below the recommended maximum tolerant level of the filler and the bonding composition, such as 160°.

Upon drying, the forming of the bath is complete replicating the traditional rolled edge narrow flanged bath tub.

The second principal embodiment is substantially identical to the first principal embodiment with the only exception being that an alternative embodiment of moulding is used, as opposed to the underside moulding of the previous embodiment. Moreover, an upper side moulding 45 is used as best shown in figure 7 of the drawings.

The upper side moulding 45 similarly comprises an inner engaging portion and an outer contoured portion 47, but this time the inner engaging portion is formed with a recess along the underside of the moulding, defining an inner flange 49 and a step 51 having a riser portion 53.

In this embodiment however, the step is disposed intermediate the distal end of the outer contoured portion and the inner flange 49 to define an accentuated outer rolled edge 55.

Furthermore, the outer surface 57 of the outer contoured portion 47 is of a much more pronounced convex curvature to simulate the more antiquated and hence more aesthetically appealing old style bath. The riser portion 53 is similarly disposed obliquely relative to the normal of the transverse extent of the moulding and is commensurate to the thickness of the peripheral lip 17. Additionally, the inner flange 49 projects outwardly from the step a distance commensurate to the outer projection of the top portion of the lip, so that when the moulding 45 is brought into apposition with the lip 17, the outer end of the lip is disposed adjacent to the riser portion 53 of the step and defines a similar small cavity 59 which is also triangular in section, albeit disposed upon the underside of the flange.

When the upper side moulding 45 is disposed in apposed relationship with the lip 17, the outer surface 57 of the outer contoured portion at the outer end of the inner flange 49, is substantially coextensive with the inner surface 61 of the sunken portion 13 of the bath, defining another small gap between the outer end of the inner flange 39 and the proximal portion of the lip. This gap, together with the small cavity 59 is filled by a keying and bonding filler 62, as like the corresponding gaps and cavities of the preceding embodiment, so that the outer surfaces of the moulding and the lip are moulded to form a continuous and contoured outer surface extending from inside of the upper extent of the sunken portion of the bath to the outer periphery of the outer contoured portion and the underside of the lip 17.

As with the preceding embodiment, the upper side moulding 45 is temporarily clamped to the lip 17 and a series of holes 23 are drilled transversely through the overlapping portions of the inner flange 49 and the lip 17 at spaced apart locations along the entire longitudinal extent of the lip.

Female screw threads are tapped within each hole and the threaded fasteners 65 are screwed into these holes in the same manner as in the preceding principal embodiment, being coated with an appropriate bonding composition, and the protruding portions of the same are sheared off and covered with filler to present an evenly contoured surface. By adopting this type of moulding, a replica rolled edged bath with a more highly curved narrow flange is formed, as shown in figure 6 of the drawings.

The third principal embodiment is a combination in some respects of both of the preceding embodiments, but is significantly different in other respects. Moreover, as opposed to both of the preceding embodiments, instead of cutting off the expansive flange portion at a position so as to retain a marginal peripheral lip, the entire expansive flange portion is cut off at the top of the bath wall leaving a uniform peripheral edge disposed in a horizontal plane.

As shown in figure 8 of the drawings, a preformed upper moulding 71 is used as opposed to the mouldings of the previous embodiments which is particularly characterised to be attached to the peripheral edge 73 of the bath.

The upper moulding has a complete narrow flange 75 incorporated within it so as to define an outer contoured portion 77 adjacent to and contiguous with an inner engaging portion 79 along the inner end of the flange which forms part of the wall of the bath.

In the specific embodiment of the upper moulding 71 , the arrangement of the recess of the inner engaging portion 79 defining an inner flange 81 and a step 83 having a riser portion 85, is similar to the first embodiment, except that the recess is disposed on the intended inner side of the moulding 71 and the inner flange 81 is located in apposition to the outer side of the edge 73 with the riser portion 85 being disposed in abutment to the distal end of the edge 73. Accordingly in this position, the upper surface of the outer contoured portion 77 is configured so as to be substantially contiguous and coextensive with the inner surface of the bath wall 87.

Accordingly, the upper moulding 71 is located and fixedly engaged in apposition with the edge 73 of the bath in a similar manner to the preceding embodiments and is moulded with a bonding filler, smoothed and the outer surface of the bath coated to finish the reflanging of the vessel also in a similar manner to the preceding embodiments.

The preformed mouldings described in each of the aforementioned embodiments can be formed a number of different ways. In the preferred embodiments, the moulding is made from an appropriate metal such as aluminium and extruded to the requisite cross section configuration.

In the case of forming the underside moulding 21 , the extruded material is initially cut into two rectilineal moulding sections 21a and 21b of the prescribed length, one for each end of the bath. A series of spaced apart slots 91 are cut orthogonally into the inner flange 29 of each section along regions thereof which are to be arcuately disposed relative to the peripheral lip 17 of the bath, when ultimately brought into apposition therewith. In the region to be apposed with the fully curved end of the bath, the slots are spaced apart approximately double to the spacing in the regions to be apposed to the curved corner ends of the bath. This is to facilitate bending to the differently radiused curvatures required to be adopted by the different moulding sections.

The moulding sections are then separately bent to their requisite curvatures using a specially configured jig 93 as shown in figures 9 to 11 of the drawings. The jig 93 comprises a stand 95, a template 97 mounted in an elevated position relative to the stand and a relocatable bending arm 99.

The template 97 in plan is precisely configured to the corresponding curvature of the end of the peripheral lip 17 at the opposing ends of the bath. As shown in figure 10, the fully curved end is provided at the template end 97a and the curved corner ends are provided at the template end 97b. The straight sides of the template 97 are actually shorter than the corresponding sides of the bath as the full length is unnecessary for bending purposes. The end of the template is formed with a circumferential slot 101 of slightly larger size than the inner flange 29 of each moulding section, to closely accommodate the flange therein and allow the riser portion 33 of the step 31 to abut the template end.

Three pivot holes 103 are formed in the template to pivotally locate the bending arm at three prescribed positions for bending the moulding sections to the three requisite curvatures of the bath ends. One pivot hole 103a is disposed at the centre of the curve for the fully curved end 97a and the pivot holes 103b are disposed at the respective centres of the curves for the curved corner ends 97b.

The bending arm 99 comprises an upper member 99a, a lower member 99b and a handle 99c. The upper and lower members 99a and 99b are spaced apart and coextend to fit over the top and bottom surfaces of the template respectively so that they can be pivotally mounted to the template via a nut and bolt pivot pin arrangement 105 at any of the pivot holes 103 proximate to their ends, with the handle 99c projecting radially outwardly from the template 97.

Depending upon the particular pivot hole 103 (and hence radius of curvature) to which the bending arm is mounted, a resting bolt 107 is disposed along the upper member 99a to engage the top surface of the template 97 and support the bending arm in its radial and vertically spaced position relative to the template, reducing the shear force on the pivot pin arrangement 105. Importantly, a cylindrical bending wheel 109 is pivotally mounted between the upper and lower members 99a and 99b at a precise radius from the pivot pin arrangement 105 to define a nip 111 between the inner side thereof and the outer end of the template 97. This nip is precisely configured to locate and pinch a moulding section 21a or 21b, interposed between the bending wheel 109 and the template 97 as shown in figures 10 and 11 , into apposition with the template as the bending arm 99 is rotated about the pivot hole 103 and pin arrangement 105. The bending wheel 109 can be disposed in one of two positions, depending upon the particular pivot hole 103 to which the bending arm 99 is mounted. In the case of the smaller radiused curved corner ends, the bending wheel is mounted closer to the pivot pin arrangement than in the case of the larger radiused curved end. In either case, the size of the nip is the same.

Prior to commencing the bending operation, the particular moulding section for the particular end of the bath is fixedly located to the template so that a portion of the inner flange 29 of the moulding section is disposed in apposition to the slot 101 with the adjacent riser portion 33 abutted to the corresponding end of the template. Importantly, the region of the moulding section to be curved is precisely located so that its orthogonal slots are correspondingly disposed with respect to the curved end of the template. Once fixed with the moulding interposed between the wheel and the template, the bending arm is simply rotated about the pivot pin, forcedly bending the moulding section into apposition with the template.

After both sections are bent in this manner, they are transferred to a welding jig 113 as shown in figures 12 and 13. The welding jig simply comprises a stand 115 fitted with an elevated and rotatable welding table 117. The welding table comprises a pair of end plates 119 corresponding to the external shape of the peripheral lip 17 of the bath. The plates are precisely and fixedly spaced apart to align their outer peripheral edges with the corresponding peripheral end of the peripheral lip 17 of the actual bath. The table 117 is locked in the horizontal position and the bent moulding sections 21a and 21b are fitted upside down and clamped to the outer periphery of the correspondingly shaped plates, so that the ends of each section are butted to the adjoining ends of the other section, as shown in figure 12. The plates are configured so that the riser portions of the bent moulded sections abut with the outer edges of the plates when the sections are correctly positioned upon the plates. Once in this position, the adjoining ends of the moulded sections can be welded together, the table being rotated into the desired position to easily effect a complete circumferential weld around the abutting ends. ln an alternative embodiment, the preformed moulding is wholly cast to the requisite cross sectional shape and annular configuration using cast iron. Although less labour intensive, this method is usually more expensive and less precise in the detail that can be achieved by using the metal extrusion method of preforming the mouldings. Consequently, the extrusion method is preferred for the formation of mouldings.

It should be appreciated that although the invention has been described with respect to two principal embodiments of methods of reflanging a bath, and secondary embodiments of the bath and mouldings used therewith, the invention is not limited to such embodiments, and other embodiments of the invention may be envisaged. Accordingly, the invention is not limited to the particular embodiments herein described.

Claims

1. A method for reflanging a broadly flanged vessel including:

fixedly engaging said moulding and said edge in said apposition;

moulding said moulding and said edge with a bonding filler to form a continuous and contoured outer surface extending from inside the vessel to the outer periphery of said outer contoured portion; and

smoothing and coating said outer surface to finish reflanging the vessel.

2. A method as claimed in claim 1 including roughing the surface of said edge to facilitate keying of said filler thereto.

3. A method as claimed in claim 1 or 2, wherein said inner engaging portion includes a recess to define an inner flange, and the locating of said pre¬ formed moulding includes overlapping said inner flange with said edge.

4. A method as claimed in claim 3, wherein said inner engaging portion is formed with a keyway within said recess to confront said edge when disposed in apposition thereto to facilitate keying of said filler thereto.

5. A method as claimed in any one of the preceding claims, wherein the fixed engaging of said moulding and said edge includes: temporarily clamping said moulding and said edge together; drilling a series of holes transversely through the overlapping portions of said inner flange and said edge at spaced apart locations along the entire circumferential extent of said edge; tapping each of said holes to cut a screw thread therein; and screwing a threaded fastener through each of said holes to permanently fix said moulding and said edge in said apposition.

6. A method as claimed in claim 5, wherein said threaded fastener includes a bolt and nut arrangement, and the fixed engaging of said moulding and said edge includes coating a said bolt with a bonding composition prior to screwing the same through a said hole and with a said nut to promote bonding and affixture to the side of the hole and threaded engagement with said nut.

7. A method as claimed in claim 6 including shearing protruding portions of said nut and bolt arrangement after said bonding and affixture.

8. A method as claimed in any one of the preceding claims, including cutting a keyway into the end of said edge prior to locating said moulding in apposition thereto.

9. A method as claimed in claim 8 as dependent on claim 4, wherein the moulding keyway and the edge keyway are disposed oppositely each other when said moulding and said edge are brought into apposition with each other.

10. A method as claimed in any one of the preceding claims, wherein the fixed engagement of said moulding and said edge includes: temporarily clamping said moulding and said edge together; introducing a fluid keying filler into the interface between said edge and said moulding to occupy said keyway(s); and allowing said keying filler to set.

11. A method as claimed in claim 10, wherein said fluid keying filler is a molten metal.

12. A method as claimed in any one of the preceding claims, wherein said edge comprises a marginal peripheral lip of substantially constant lateral extent and corresponding shape to the outline of the sunken portion of the vessel.

13. A method as claimed in any one of the preceding claims, wherein said bonding filler is a plastic putty.

14. A method as claimed in any one of claims 3 to 13, wherein said recess is disposed on the intended upper side of said moulding and defines a step having a riser portion with a transverse extent commensurate to the thickness of said lip, and the locating of said pre-formed moulding includes locating said inner flange in apposition to the underside of said lip and said riser adjacent to the outer periphery of said lip, so that the upper surface of said outer contoured portion of said moulding is substantially coextensive with the upper surface of said lip.

15. A method as claimed in any one of claims 3 to 13, wherein said recess may be disposed on the intended underside of said moulding and defines a step having a riser portion with a transverse extent commensurate to the thickness of said lip, and the locating of said pre-formed moulding includes locating said inner flange in apposition to the upper side of said lip and said riser portion adjacent to the outer periphery of said lip, so that the upper surface of said outer contoured portion of said moulding is substantially contiguous and coextensive with the inner surface of the sunken portion of said vessel.

16. A method as claimed in any one of claims 3 to 13, wherein said edge comprises the top of the vessel wall below the expansive flange portion of the vessel.

17. A method as claimed in claim 16, wherein said recess is disposed on the intended inner side of said moulding and defines a step having a riser portion with a transverse extent commensurate to the thickness of said edge, and the locating of said pre-formed moulding includes locating said inner flange in apposition to the outer side of said edge and said riser adjacent to the outer periphery of said edge, so that the upper surface of said outer contoured portion of said moulding is substantially contiguous and coextensive with the inner surface of the sunken portion of said vessel.

18. A method as claimed in any one of the preceding claims; including forming said pre-formed moulding by extrusion to the requisite cross-section configuration, cutting a series of spaced apart slots orthogonally along said inner engaging portion at regions thereof which are to be arcuately disposed relative to said edge when brought into apposition therewith, and bending said moulding along said regions to adopt the requisite curvature for apposed relationship with said edge.

19. A method as claimed in claim 18, wherein said moulding is initially formed in at least two discrete sections and pursuant to said bending of each section, said sections are welded together to form a unitary pre-formed moulding for use in the remainder of the method.

20. A method as claimed in any one of claims 1 to 17, including forming said pre¬ formed moulding by casting to the requisite cross-section configuration.

21. A reflanged vessel formed in accordance with the method defined in the preceding aspect of the invention.

22. A moulding for reflanging a broadly flanged vessel including:

an inner engaging portion for engaging a peripheral edge of said vessel and an outer contoured portion, said inner engaging portion having a recess to define an inner flange and a step having a riser portion with a transverse extent commensurate to the thickness of the peripheral edge.

23. A moulding as claimed in claim 22, wherein said inner flange projects outwardly from said step a distance commensurate to the outer projection of the edge.

24. A moulding as claimed in 22 or 23, wherein said outer contoured portion is convexly shaped.

25. A moulding as claimed in any one of claims 22 to 24, wherein said step is disposed intermediate of and contiguous with said inner engaging portion and said outer contoured portion, such that said recess is disposed on the intended upper side of said moulding.

26. A moulding as claimed in any one of claims 22 to 24, wherein said step may be disposed oppositely of said outer contoured portion such that said recess is disposed on the intended underside of said moulding.

27. A moulding as claimed in any one of claims 22 to 24, wherein said step may be disposed intermediate of and contiguous with said inner engaging portion and said outer contoured portion, such that said recess is disposed on the intended inner side of said moulding.

28. A moulding as claimed in any one of claims 22 to 27, wherein said step is formed with a key way projecting inwardly thereof and extending longitudinally along the moulding.

29. A method for reflanging a broadly flanged vessel substantially as herein described with reference to the accompanying drawings where appropriate.

30. A reflanged vessel substantially as herein described with reference to the accompanying drawings where appropriate.

31. A moulding substantially as herein described with reference to the accompanying drawings where appropriate.