Patent Application
20200352397
The present disclosure relates to an article of sanitary ware, in particular, but not exclusively a shower tray. The disclosure also relates to methods of manufacture of an article of sanitary ware, e.g. a shower tray.
Shower trays comprising an acrylic-capped acrylonitrile butadiene styrene (ABS) upper layer adhered to and supported by a resin-stone base are known. Such trays are usually manufactured by pouring a resin-stone filler into a mold containing a shell of acrylic-capped ABS pre-formed to the desired shape of the top and sides of the shower tray and hardening the filler to form the base. In this way, the acrylic-capped ABS upper layer forms the outer surface of the exposed parts of the tray in its installed position and the filler supports the upper layer and forms an underside of the tray that contacts the surface on which the tray is installed.
WO2005/011455 discloses shower trays and like articles, in which an outer shell of plastics material encases a core of stone-resin material. The outer shell comprises upper and lower members provided with formations that co-operate to locate and align the members, wherein overlapping regions of the formations are removed after the core is formed to provide a base for the article and a hole for wastewater.
A problem of known acrylic-capped ABS shower trays is that the weight of the trays can make lifting and carrying the trays during installation difficult. Lifting and carrying heavy trays can result in injury to the lifter and/or cause the lifter to drop the tray resulting in damage to the tray. Typically, 800 mm by 800 mm trays can weigh from around 26 kg to 33 kg.
Shower trays comprising a plastic cap or shell filled with a stone-resin material are sometimes called polymer-concrete shower trays.
Low level shower trays are known. Conveniently, low level shower trays may be configured such that they can be installed such that they are level or nearly level with a floor of a room, e.g. a shower room or wet room, in which they are installed. Accordingly, a user does not have to step up or down into the shower tray when entering or exiting a shower cubicle or shower enclosure comprising the low level shower tray. Low level shower trays may be preferred from an aesthetic perspective, in order to fit in with a modern design aesthetic. Low level shower trays may also be well suited for users with limited or impaired mobility. Further, low level shower trays may also be of reduced weight when compared to conventional shower trays, making installation easier.
For any shower tray, it is important that the shower tray can withstand impacts, mechanical stresses and strains during installation and use.
A low level shower tray typically has a relatively shallow profile; hence the structure of the shower tray may be much thinner than that of conventional trays. Therefore providing a low level shower tray with adequate or even improved impact resistance and/or mechanical stress and/or strain properties can be challenging. Ideally, such mechanical properties should be achieved whilst keeping the weight of the shower tray to an acceptable level for installation.
It would be advantageous to provide an improved shower tray that addresses these and other issues.
An exemplary embodiment relates to an article of sanitary ware that includes a hollow shell comprising a first surface adapted to provide a water collection surface and a second surface opposed to the first surface and comprising a pattern of recesses with ribs therebetween. A filler material is disposed within the shell, the filler material forming a continuous structure within the shell. The depth of the recesses varies with position in such a way that the minimum distance between the water collection surface and bases of the recesses is maintained substantially constant.
Another exemplary embodiment relates to an ablutionary installation comprising an article of sanitary ware that includes a hollow shell comprising a first surface adapted to provide a water collection surface and a second surface opposed to the first surface and comprising a pattern of recesses with ribs therebetween. A filler material is disposed within the shell, with the filler material forming a continuous structure within the shell. The depth of the recesses varies with position in such a way that the minimum distance between the water collection surface and bases of the recesses is maintained substantially constant.
Another exemplary embodiment relates to a method of manufacturing an article of sanitary ware. The method includes forming a shell and disposing a filler material within the shell, with the filler material forming a continuous structure within the shell. The shell includes a first surface adapted to provide a water collection surface and a second surface opposed to the first surface. The second surface includes a pattern of recesses with ribs therebetween, the depth of the recesses varies with position in such a way that the minimum distance between the water collection surface and bases of the recesses is maintained substantially constant.
Example embodiments will now be described with reference to the accompanying drawings, in which:
According to an exemplary embodiment, a first aspect provides an article of sanitary ware comprising a hollow shell; wherein a filler material is disposed within the shell, the filler material forming a continuous structure within the shell, the shell comprising: a first surface adapted to provide a water collection surface; and a second surface opposed to the first surface; wherein the second surface comprises a pattern of recesses with ribs therebetween, the depth of the recesses varies with position in such a way that the minimum distance between the water collection surface and bases of the recesses is maintained substantially constant.
The filler material may form a continuous web within the shell. It may be that the ribs comprise the filler material.
The article of sanitary ware may be a shower tray. The shower tray may have any shape and dimensions. The shower tray may be generally circular, ovoid, rectangular, square, pentagonal or a quadrant in shape. A floor may form at least a portion of the water collection surface of the shower tray. The floor may be the portion of the shower tray upon which a user typically stands during use. The floor may be inclined. The shower tray may be a low level shower tray.
The floor of the shower tray may be bounded by a rim. One or more side walls may extend from the edges of the floor. The term side wall may refer to any face which extends between the floor and the rim along one or more peripheral edges where the floor and the rim do not meet. In a preferred embodiment, the or each side wall may not extend above an uppermost point of the floor. In a further preferred embodiment, the shower tray may only have a sidewall along one peripheral edge of the floor. At one or more edges of the floor, the floor may gradually slope up to the rim. The floor may slope to the rim at edges of the floor with no sidewall.
The shower tray may have a height of up to 100 mm, preferably up to 60 mm, more preferably up to 50 mm, yet more preferably up to 40 mm and yet more preferably up to 30 mm. In a preferred embodiment, the shower tray may have a height of 26 mm.
The pattern of recesses may extend across at least a portion of the second surface. The pattern of recesses may extend across at least 50% of the second surface. In preferred embodiments the pattern of recesses may extend across at least 60%, preferably at least 70%, more preferably at least 80%, yet more preferably at least 90%. Most preferably the pattern of recesses may extend across substantially all of the second surface.
The pattern of recesses may comprise a repeating pattern. The repeating pattern may repeat in one or more, e.g. one or two, directions. For instance, the repeating pattern may repeat in a first direction and in a second direction. The first direction and the second direction may be perpendicular to one another.
The pattern of recesses may be symmetrical about at least one line of symmetry. For instance, the pattern of recesses may be symmetrical about a first line of symmetry and a second line of symmetry. The first line of symmetry may be perpendicular to the second line of symmetry.
Each recess may be of any shape and dimensions. Each recess may have a longest lateral dimension of up to 150 mm, preferably up to 120 mm, more preferably up to 100 mm, yet more preferably up to 80 mm or most preferably up to 50 mm.
Each recess may be curved, e.g. round or ovoid, curvilinear or polygonal in cross-section. At least some of the recesses in the repeating pattern may tessellate with one another. At least some of the recesses in the repeating pattern may be polygonal in cross-section, e.g. triangular, quadrilateral, pentagonal, hexagonal, heptagonal, octagonal, nonagonal or decagonal. At least some of the recesses in the repeating pattern may have the form of a regular polygon in cross-section, e.g. an equilateral triangle, a square or a regular hexagon.
The shell may be configured such that a distance between any given point on the first surface and a corresponding point on the second surface may be at least 2 mm, preferably at least 5 mm.
The filler material may occupy a major portion of an internal volume of the shell. The filler material may occupy more than 60%, preferably more than 70%, more preferably more than 80% or yet more preferably more than 90% of the internal volume of the shell. In preferred embodiments the filler material may occupy substantially all of the internal volume of the shell.
The filler material may act to add mechanical strength and/or rigidity to the sanitary article. The filler material may bond or be bonded to the shell or a portion thereof.
The filler material may comprise a stone-resin material, e.g. a concrete. The filler material may comprise a polymeric material. The filler material may comprise a composite material. The filler material may comprise a cellular material such as a foam or a honeycomb material. The filler material may comprise a honeycomb material, in which at least some of the cells are filled at least partially with another material such as a foam.
The filler material may have been cured within the shell.
The filler material may comprise a composite filler. The composite filler may be formed from curing a resin-stone mix, e.g. of limestone, calcium carbonate, dicyclopentadiene (DCPD) resin and a catalyst.
The continuous structure may be of varying thickness throughout its extent. For instance, the continuous structure may have one or more regions of a minimum thickness, for instance of 2 mm or preferably 5 mm, and regions of greater thickness than the minimum thickness. Thus, the filler material may provide adequate strength and rigidity to the article of sanitary ware, e.g. shower tray, whilst minimizing the weight of the article of sanitary ware.
The shell may comprise, or consist essentially of, a plastics material.
The or a floor may be made of materials that provide a hardwearing, scratch-resistant outer surface with softer material underneath for absorbing impacts during use. For instance, the or a floor may be made of an acrylic-capped ABS material. The acrylic material forms the hardwearing, scratch-resistant outer surface and the softer underlying ABS material absorbs impacts. The or a floor may be provided with one or more anti-slip features (not shown) such as protrusions, ridges or roughened regions.
The or a floor may be of uniform thickness. The or a floor may have a thickness of at least 1 mm and/or up to 5 mm. The ratio of the thickness of the ABS to acrylic may be at least 5:1 and/or up to 15:1. For instance, the ratio of the thickness of the ABS to acrylic may be 9:1. In an embodiment, the or floor may be 2 mm thick with a skin of acrylic 0.2 mm thick and a sub-layer of ABS 1.8 mm thick.
At least a portion of the first surface may be coated with, or have impregnated therein, an antimicrobial agent.
The second surface may comprise one or more through holes that are large enough to permit air or other gases to pass through them without being large enough for any filler material, if present, to pass through.
The article of sanitary ware, e.g. the shower tray, may comprise a waste adapted to be connected to a waste pipe. The waste may comprise an elongate aperture.
The second surface may be provided with one or more attachment features for receiving legs or feet. Each attachment feature may comprise a socket. The attachment features may be configured to engage with the legs or feet in any suitable manner, e.g. by a push interference fit or by screwing.
The shell may comprise two or more shell members. The shell or shell members may be made by any suitable process. The shell or shell members may comprise plastics materials. The shell or shell members may be made for example by vacuum molding.
For instance, the shell may be formed of a first shell member and a second shell member. The first shell member may include the first surface. The second shell member may include the second surface.
The first shell member may be made of materials that provide a hardwearing, scratch-resistant outer surface with softer material underneath for absorbing impacts during use. For instance, the first shell member may be made of an acrylic-capped ABS material. The acrylic material forms the hardwearing, scratch-resistant outer surface and the softer underlying ABS material absorbs impacts.
The first shell member may be of uniform thickness. The first shell member may have a thickness of at least 1 mm and/or up to 5 mm. The ratio of the thickness of the ABS to acrylic may be at least 5:1 and/or up to 15:1. For instance, the ratio of the thickness of the ABS to acrylic may be 9:1. In an embodiment, the first shell member may be 2 mm thick with a skin of acrylic 0.2 mm thick and a sub-layer of ABS 1.8 mm thick.
The second shell member may be made from a plastics material. The second shell member may be made from ABS. The second shell member may be of uniform thickness. The second shell member may have a thickness of at least 1 mm and/or up to 5 mm.
The shell members may be provided with formations that co-operate to locate and align the members. In embodiments, overlapping regions of the formations may be removed during manufacture of the article of sanitary ware.
The article of sanitary ware may be installed at a location to provide or as part of an ablutionary installation. For instance, the shower tray may be installed within a shower cubicle or shower enclosure. The ablutionary installation may be in a room within a residential, commercial or industrial building. The ablutionary installation may be within a cabin of a vehicle such as a boat.
When installed as part of a shower enclosure or shower cubicle, the second surface of the shower tray may be in direct contact with an installation surface. The installation surface may comprise a sand bed. The recesses and ribs therebetween may facilitate settling of the shower tray on the sand bed during installation. Alternatively, the shower tray may be raised from the installation surface by one or more feet or legs.
The or a waste of the shower tray may be connected to a wastepipe for conveying waste water towards a drain.
A shower comprising one or more sprayers for dispensing water may be located within the shower cubicle or shower enclosure. The shower may be arranged or may be arrangable such that water dispensed therefrom is directed towards the water collection surface.
A second aspect provides a method of manufacture of an article of sanitary ware comprising:
forming a shell, disposing a filler material within the shell, the filler material forming a continuous structure within the shell, the shell comprising: a first surface adapted to provide a water collection surface; and a second surface opposed to the first surface; wherein the second surface comprises a pattern of recesses with ribs therebetween, the depth of the recesses varies with position in such a way that the minimum distance between the water collection surface and bases of the recesses is maintained substantially constant.
The method may comprise the steps of: providing a first shell member; placing a filler material within the first shell member; and encasing the filler material by completing the shell with one or more further shell members.
The method may further comprise applying pressure to the shell with the or a filler material encased therein.
Additionally or alternatively, the shell with the filler material encased therein may be held at a predetermined, e.g. elevated temperature, for a predetermined period of time.
The method of manufacture may be used to make an article of sanitary ware according to the first aspect.
Except where mutually exclusive, any of the features of the first aspect may be employed mutatis mutandis in the second and other aspects.
Referring now to
The low level shower tray 1 is rectangular in form. The low level shower tray 1 comprises a pair of opposing longer edges 5a, 5b and a pair of opposing shorter edges 6a, 6b. In the example embodiment, the longer edges 5a, 5b each have a length of 1800 mm and the shorter edges 6a, 6b each have a length of 800 mm. In embodiments, the shower tray may have other shapes and dimensions.
The low level shower tray 1 comprises a floor 2. The floor 2 may comprise one or more anti-slip features (not shown) such as protrusions, ridges or roughened regions. The floor 2 slopes downwardly away from a first one of the opposing longer edges 5a in a direction towards a second one of the opposing longer edges 5b. A rim 3 bounds the floor 2 on three sides. The rim 3 joins the floor 2 to the pair of opposing shorter edges 6a, 6b and to the second one of the opposing longer edges 5b. At the first one of the opposing edges 5a, the floor 2 extends to the edge 5a.
Along the edge of the floor 2 proximal to the second of the opposing longer edges 5b, a sidewall 16 connects the floor 2 to the rim 3. The floor 2 slopes or curves gradually up to the level of the rim 3 at the edges of the floor 2 proximal to the pair of opposing shorter edges 6a, 6b and at the first of the opposing longer edges 5a. Since the sidewall 16 connects the floor 2 to the rim 3 at one edge, and the floor 2 slopes up to the level of the rim 3 on the other edges, the sidewall 16 does not extend above the level of the uppermost point of the floor 2.
A waste 4 is located at an edge of the floor 2 proximal to the second one of the opposing longer edges 5b. The waste 4 is located midway along the sidewall 16, between the pair of opposing shorter edges 6a, 6b. Therefore the sidewall 16 includes separate portions either side of the waste 4. The waste 4 comprises an elongate aperture extending in a direction parallel to the pair of opposing longer edges 5a, 5b. The floor 2 is configured such that water collected on the floor during operation of a shower (not shown) is directed to flow towards the waste 4. The floor 2 typically may have a slope at any given point of 1° or more to ensure the efficient flow of water towards the waste 4. The waste 4 is adapted to be connected to a waste pipe (not shown) for conveying waste water towards a drain (not shown).
In the illustrated embodiment, the low level shower tray 1 may be installed in a shower cubicle or shower enclosure in such a way that a user steps on to the floor 2 from the direction of the first one of the opposing longer edges 5a. Hence, the floor 2 directs water collected thereon away from the user's entry/exit location, which may help to limit or prevent water from inadvertently exiting the shower cubicle or enclosure on to the floor of the room in which the shower cubicle or enclosure is installed.
As can be seen clearly in
The curving of the floor 3 up to the level of the rim 3 along three sides of the shower tray has been found to reduce the overall height of the shower tray 1 whilst still providing effective water collection at the waste 4.
The elongate waste 4 of the low level shower tray 1 has been found to provide for an efficient flow of waste water out of low level shower tray 1.
In embodiments, the desired location, shape and dimensions of the waste may be determined to some extent by aesthetic considerations.
In embodiments, the waste may be located at other positions in the floor and/or may have a different shape or dimensions. In embodiments, the shower tray may comprise more than one waste.
As can be seen clearly in
The pattern of recesses is symmetrical about a first line of symmetry indicated by a first dashed line 14, which bisects the waste 4. If the waste 4 is ignored, then the pattern of recesses is also symmetrical about a second line of symmetry indicated by a second dashed line 15. The second dashed line 15 is perpendicular to the first dashed line 14.
The pattern of recesses comprises a central portion 10 located centrally on the underside 7 of the low level shower tray 1. The central portion 10 comprises an array of tessellating hexagonal recesses with six arcuate recesses 9 forming a broken ring around the hexagonal recesses.
Outside the broken ring formed by the arcuate recesses 9, a relatively short distance towards each of the opposing shorter edges 6a, 6b is a recess-free region 11. The two recess-free regions 11 are each generally circular.
Outside the central region 10, other than the two recess-free regions 11 and around the waste 4, the pattern of recesses comprises a repeating pattern of tessellating hexagonal recesses 8. The hexagonal recesses are all regular hexagons of the same lateral dimensions. The ribs of the continuous web 12 between the hexagonal recesses 8 are of a generally uniform width. The ribs of the continuous web 12 between the hexagonal recesses 8 may for example have a width of at least 5 mm, up to or at least 10 mm, up to or at least 13 mm, up to or at least 15 mm, up to or at least 20 mm or up to or at least 30 mm. In the illustrated embodiment, in which the hexagonal recesses 8 are approximately 28 mm across, the ribs of the continuous web between the hexagonal recesses 8 have a width of from 13 mm to 15 mm.
At regularly-spaced locations around the perimeter of the underside 7, there are disposed 14 attachment features 13. The attachment features 13 are adapted for receiving legs or feet (not show), which may be used to install the low level shower tray raised at a height above a surface, e.g. floor. This may provide for instance a space between the underside 7 of the low level shower tray 1 and the surface for a waste pipe (not shown) to be connected to the waste 4 without the waste pipe having to be installed under or within the surface, as would be the case if the low level shower tray 1 were installed directly onto the surface.
The underside 7 may be provided with one or more holes (not shown) that are large enough to allow air or gas to pass through without being large enough to allow any filler material encased in the shell to pass through. Such holes may have a diameter of around 1 mm or less.
By maintaining substantially constant the minimum distance between the floor or rim and the bases of the recesses in the underside of the low level shower tray, a controlled volume of a filler material may be used. Furthermore, the slope of the floor 2 required to direct liquid to the waste 4 can be formed whilst maintaining a low overall height of the shower tray 1. Also, the amount of filler material required to fill the shell is substantially less than the amount that would be required to fill a shell without the pattern of recesses on its underside, or that would be required to fill a shell with a pattern of recesses with constant depths across the underside of the low level shower tray. Accordingly, weight and cost of the shower tray may be reduced, whilst still maintaining strength.
The shell of the low level shower tray 1 comprises a plastics material, e.g. ABS. The shell is made up of two shell members. A first shell member comprises an upper portion of the shower tray and includes the floor and the rim. A second shell member comprises a lower portion of the shower tray and includes the underside. A filler material may be placed in one of the two shell members. The shell may then be completed by connecting the other of the two shell members to the one with the filler material disposed therein. Thus, the filler material may be encased within the shell.
Where the filler material is flowable, e.g. a curable mixture, the pattern of ribs formed by the recesses may help to guide the filler material to fill substantially all of the shell. In embodiments, the filler material may provide a single, continuous structure within the shell.
Load testing and comparative impact testing of a shower tray of the kind described above in relation to
The comparative impact testing was carried out in comparison with a known low profile polymer-concrete shower tray, the Flight 40 shower tray available from Kohler Mira Limited (see https://www.mirashowers.co.uk/shower-trays/products/?page=3&sort=name-asc&installation-type=rectangle).
The Flight 40 shower tray used as the reference for the comparative impact testing was. The Flight 40 shower tray has a structure as disclosed in WO2005/011455 and was manufactured according to a method disclosed in WO2005/011455. The Flight 40 shower tray used for the comparative impact testing was rectangular (1200 mm by 760 mm) and had a height of 40 mm.
The impact tests involved dropping a 25 mm-radius ball of a known weight from a height of 1 m on to a central location on the floor of the shower trays being tested to ascertain damage due to impact. Tests were carried out using balls of four different weights: 200 g; 300 g; 1000 g; and 1700 g.
The results of these impact tests are shown in Table 1 below. Tray 1 refers to the comparative reference, i.e. the Flight 40 shower tray. Tray 2 refers to the low level shower tray illustrated in
Taking for example the results from the impact tests carried out with the second lightest (300 g) ball, it can be seen that for Tray 2, the stress at the top skin was 13.58 MPa, the stress at the lower skin was 7.41 MPa, the strain at the top skin was 0.5% and the strain at the lower skin was 0.4%. The corresponding values for Tray 1 were all 34.06 MPa, 10.49 MPa, 0.9% and 0.4% respectively.
Generally, it can be seen that the stress and strain in Tray 2 are typically lower than in Tray 1. The stress may be almost halved and the strain may be reduced by up to two thirds.
Accordingly, Tray 2 may be more robust than Tray 1, i.e. better able to withstand impacts during installation and use.
Without wishing to be bound by any theory, it is believed that the better impact test results for Tray 2 than Tray 1 may be attributable to mechanical stresses being well distributed through the continuous web by the pattern of recesses and ribs therebetween. Accordingly, there may be a reduced chance of cracks developing in Tray 2.
The low level shower tray 1 of
A first step 61 comprises providing a first shell member. The first shell member may comprise a plastics material. The first shell member may constitute an upper part of a shower tray (i.e. a part of a shower tray comprising a floor) or a lower part of a shower tray (i.e. a part of a shower tray comprising an underside).
A second step 62 comprises placing a filler material within the first shell member. Placing the filler material within the first shell member may be done by pouring the filler material. The filler material may comprise a stone-resin material.
A third step 63 comprises encasing the filler material by completing the shell with one or more further shell members. For example, a second shell member may be attached to the first shell member to form the shell and encase the filler material therein. The second shell member may comprise a plastics material. The first shell member may constitute a first part of an article of sanitary ware such as an upper part of a shower tray (e.g. a part of a shower tray comprising a floor) or a lower part of a shower tray (i.e. a part of a shower tray comprising an underside) and the second shell member may constitute a second part of the article of sanitary ware, e.g. the other of the upper part of the shower tray or the lower part of the shower tray.
A fourth step 64 comprises, if required, applying pressure to the shell with the filler material encased therein, to promote bonding of the filler material to the first shell member and/or the second shell member and/or to promote curing of the filler material. Pressure may be applied for any suitable period of time. Additionally or alternatively, the shell with the filler material encased therein may be held at a predetermined, e.g. elevated temperature, for a predetermined period of time, to promote bonding of the filler material to the first shell member and/or the second shell member and/or to promote curing of the filler material.
The method of manufacture may comprise further applications of pressure for predetermined periods of time.
The method of manufacture may comprise one or more additional machining or finishing steps.
It will be understood that various modifications and improvements can be made without departing from the concepts disclosed herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to all combinations and sub-combinations of one or more features disclosed herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1801202.1 | Jan 2018 | GB | national |
The present application is a Continuation of International Application No. PCT/GB2019/050150, filed Jan. 18, 2019, which claims priority to and the benefit of United Kingdom Patent Application No. GB 1801202.1, filed Jan. 25, 2018. The entire disclosures of International Application No. PCT/GB2019/050150 and United Kingdom Patent Application No. GB 1801202.1 are incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/GB2019/050150 | Jan 2019 | US |
| Child | 16938447 | US |
