AU2018326280B2

AU2018326280B2 - Shower base

Info

Publication number: AU2018326280B2
Application number: AU2018326280A
Authority: AU
Inventors: Jason Cong
Original assignee: Icon Plastics Pty Ltd
Current assignee: Icon Plastics Pty Ltd
Priority date: 2017-08-31
Filing date: 2018-08-31
Publication date: 2024-08-29
Anticipated expiration: 2038-08-31
Also published as: AU2018326280A1; WO2019040970A1

Abstract

A shower base attachment (10) comprising an internally threaded substantially cylindrical sleeve (20) extending normal to a general plane of the shower base (40), the attachment including: a recess (48) forming an entrance in an upper region of an outlet (46) of the shower base; an externally threaded cylindrical insert (50) receivable within the sleeve whereby the insert is axially moveable within the sleeve, the insert adapted to receive a grate support (62) having a downwardly depending skirt (66) engageable with the upper periphery (52) of the insert and is received within the space defined by the recess, the grate support (62) overlapping part or all of the recess such that at least part of the support extends laterally beyond the footprint of the recess, wherein any leakage between the shower base and the grate support is diverted internally of the sleeve.

Description

SHOWER BASE ATTACHMENT FIELD OF INVENTION

This invention relates to a shower base attachment. More particularly, this invention relates to a shower base with an adjustable level grill.

BACKGROUND ART

The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion should not be assumed to relate to what is commonly or well known by the person skilled in the art, but to assist in the inventive process undertaken by the inventor and in the understanding of the invention.

Moulded shower bases may be moulded so that they are integrally or unitarily formed from a single moulded material. Moulded shower bases generally come with a preformed central outlet which, in some designs, extends substantially beyond the general plane of the shower base. However, such moulded shower bases are typically relatively heavy and this adds to the cost of transport.

A primary problem with current shower bases is that the seal between tiles or other aesthetic and functional floor surfaces laid on the upper surface of the shower base require a perfect seal between the shower base covering and the outlet. Over time, due to wear and deterioration in the seals surrounding the opening, water may leak down the outside of the sides of the outlet and through the join between the outlet and the receiving waste water pipe telescopically engaged in the outlet cylinder.

An object of the present invention is to ameliorate the aforementioned disadvantages of the prior art or to at least provide a useful alternative thereto.

STATEMENT OF INVENTION

The invention according to one or more aspects is as defined in the independent claims. Some optional and/or preferred features of the invention are defined in the dependent claims. Accordingly, in one aspect of the invention the following is provided:

A shower base attachment comprising an internally threaded substantially cylindrical sleeve extending normal to a general plane of the shower base and defining a recess including an upper recess that is continuous with a lower recess, the attachment including:

the upper recess forming an entrance in an upper region of an outlet of the shower base; an externally threaded cylindrical insert receivable within the sleeve, whereby the insert is axially moveable within the sleeve, the insert adapted to receive a grate support having a downwardly depending skirt engageable with the upper periphery of the insert and is received within the space defined by the upper recess, the sleeve having a lower portion that defines the lower recess, the grate support overlapping part or all of the lower recess such that at least part of the support extends laterally beyond the footprint of the lower recess, wherein any leakage between the shower base and the grate support is diverted internally of the sleeve.

A shower base attachment comprising an internally threaded and substantially cylindrical sleeve defining a recess including an upper recess that is continuous with a lower recess, the cylindrical sleeve adapted to extend normal to a general horizontal plane of the shower base, the attachment including:

the upper recess including an entrance in an upper region of an outlet of the shower base; and an externally threaded cylindrical insert receivable within the sleeve, the sleeve having a lower portion that defines the lower recess,

wherein the insert is:

axially moveable within the sleeve;

adapted to receive a grill support which: has a downwardly depending skirt engageable with the upper periphery of the insert; and

is received within the space defined by the upper recess; and

overlaps part or all of the lower recess such that at least part of the grill support extends laterally beyond the footprint of the lower recess, any leakage between the shower base and the grill support is diverted internally of the sleeve.

SHOWER BASE

The shower base may be provided in any suitable form. The shower base will generally comprise a broad drainable upper surface that is, when lying substantially horizontal as in situ, substantially planar with a shallow downward gradient to the outlet. The shower base may be any number of shapes about its periphery, according to style and installation parameters. For example, the shower base may be circular, oval-shaped, rectangular or otherwise polygonal. The shower base may be made out of mouldable or castable material, such as stainless steel, aluminium, polymeric materials or ceramics, or composite materials thereof.

OUTLET The outlet may be located at any suitable position in the shower base whereby to effectively drain water from the shower base. The outlet may be positioned on a corner of the shower base. The outlet may be positioned between corners on or near one side of the shower base. The outlet is preferably located in a central region of the shower base. The shower base may be continuous, and integrally formed, with the sleeve. The sleeve may form part of the outlet. Accordingly, the shower base and outlet, including the sleeve, may be formed from a unitary piece. The shower base and the sleeve may be integrally formed.

Alternatively, the outlet or the sleeve may be formed from composite materials. The outlet may include a substantially cylindrical sleeve base which may be mechanically bound to the shower base main panel. The sleeve base may be bound to the main panel by overmoulding the shower base material onto the sleeve base.

The outlet includes a circular ledge at its upper end that defines an upper recess in the space below the grill support in situ. When the insert is threadably engaged within this sleeve, together with the upper end wall of the insert, the upper recess defines an annular groove or channel. Accordingly, water leakage may be prevented or restricted from entering the outlet through the grill. Therefore, the water may be directed via the upper recess internally relative to the sleeve and between the insert wall and the sleeve, so that no undesirable leakage of water occurs and water disposal is confined to the outlet.

The ledge may be formed by an upper surface of the radial flange whereby the radial flange is substantially in the form of a circular hollow disc integrally formed with the wall of the sleeve.

SLEEVE BASE

The sleeve base may include a lateral or radial flange. The flange may be in the form of a full and continuous ring extending around the upper edge of the sleeve. At the sleeve's upper end the flange may extend radially outwardly from a sleeve base wall. The flange may be in the form a hollow disc with its edge meeting the side or the upper edge of a wall forming part of the sleeve base.

Alternatively, the flange may take the form of two or more radial spokes that may be circumferentially spaced around the sleeve base wall. In overmoulding the sleeve base, the shower base material may encompass the flange. The overmoulded material may extend down the outer side of the sleeve base wall. Accordingly, the outer wall of the sleeve may be unitarily or integrally formed with the main body of the shower base, with the sleeve base forming an inner wall or layer of the outlet. The flange may further include an upstanding circular rib or vein extending coaxially around the upper surface of the flange. The rib or vein may provide further mechanical engagement of the sleeve base to the shower base material that is overmoulded thereon. Whether the sleeve is entirely integrally formed with the shower base material or includes a separately formed sleeve base, the insert may be constructed in the same manner for both versions. The insert may be adapted to threadably cooperate with complementary internal threading on the internal surface of the sleeve. GRILL The grill or grate may be square or circular-shaped. The grill may comprise a housing that rests or nests neatly within the upper recess. The nesting grill may be circular in shape. Alternatively, the grill may sit above and spaced from the shower base upper surface so that at least part of the grill support overhangs the outlet or partially extends beyond the footprint of the outlet. The overhanging grill may be square or rectangular in shape. The grill support may include a downwardly extending skirt that engages with the outlet. For example, the downwardly extending skirt may receive the upper wall of the insert and be mounted thereon. Therefore, the space continuous with the perforated or slotted grill is in sealed communication with the inner space of the outlet, i.e. the inner space of the insert. BRIEF DESCRIPTION OF THE DRAWINGS The invention may be better understood from the following non-limiting description of preferred embodiments, in which: Figure 1 is an upper perspective sectional view of a shower base attachment according to a first embodiment of the invention; Figure 2 is an upper perspective sectional view of a shower base attachment according to a second embodiment of the invention; Figure 3 is an upper perspective sectional view of a shower base attachment according to a third embodiment of the invention; Figure 4 is an upper perspective sectional view of a shower base attachment according to a fourth embodiment of the invention; Figure 5 is an upper perspective sectional view of the shower base attachment of the fourth embodiment shown in Fig. 4; Figure 6 is an upper perspective sectional view of a shower base attachment according to a fifth embodiment of the invention; and Figure 7 is an upper perspective sectional view of a shower base with an attachment installed according to the first, second or fourth embodiments of the invention. DETAILED DESCRIPTION OF THE DRAWINGS Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. Referring to Fig. 1, there are shown a shower base attachment 10 comprising a sleeve 20 defining an outlet 44. The sleeve 20 is integrally formed and unitarily moulded with the main body 41 of the shower base 40 that extends in a generally horizontal plane P. The sleeve 20 has a cylindrical axis A that extends in a direction substantially normal to the main body 41. The outlet 44 is located in plan view substantially central to the main body 41 and the upper surface of the main body 41 forms a panel that is generally inclined in a shallow gradient downwardly from the perimeter of the main body 41 to the outlet 44 for the purposes of effective drainage. The internal wall of the sleeve 20 includes an internal thread 28 that is adapted to the complementarily and threadably cooperate in engagement with an external thread 58 of a sleeve insert 50. Consequently, the sleeve insert 50 is adapted to be axially adjustable within the sleeve 20 by rotation about the axis A. The insert 50 rotates through counter rotation of the threaded engagements 28, 58 to effect upward or downward axial travel of the insert 50 within the sleeve 20. The upper wall 54 of the insert 50 may terminate in a upper circular edge 53 that provides a seat for a grill support 62. The grill support 62 may include a corresponding, downwardly depending cylindrical wall in the form of a skirt 66. The skirt 66 is adapted to fit neatly in coaxial engagement about the exterior of the upper wall 54, such that an internal lip 67 extending radially inwardly from the upper end of the skirt 66 rests on the upper edge 53 of the upper wall 54. The internal lip 67 and grill support 62 are continuous and integrally formed. The internal lip 67 and grill support 62 lie in a common grill support plane G. In section, the grill support 62 and the internal lip 67 on the one hand, and the skirt 66 on the other, form a T-join. The grill support 62 supports a grill fascia 68 that is received on or within the grill support 62 and includes regular elongate slots 69 to allow egress of water from the upper surface of the base body 41 down the outlet 46.

Referring to the Figs. 2 - 7, like features compared to Fig. 1 will be referred to using like reference numerals. There is shown a shower base 40 having an attachment 10 comprising an internally threaded, substantially cylindrical, sleeve 20. The sleeve 20 is over-moulded and set in the polymeric material of the shower base 40. The overmoulded material of the shower base 40 forms a downwardly depending outlet 44. The outlet 44 includes a thin-walled, external cylindrical wall 46 that provides the outer wall of the outlet 44. At the outlet's 44 upper end, there is provided an upper shower base recess 48 forming part of a recess 26a,48 defined by the sleeve 20 that is continuous with a lower recess 26a defined by a lower portion 26 of the sleeve 20. The upper recess 48 has an upwardly extending outer annular wall 45 defining the upper mouth of the drain outlet 44 set in the main body 41. The shower base upper recess 48 is defined at its radial outward perimeter by the annular wall 45 and has a wider diameter than the thin cylindrical wall 46. A cylindrical axis A of the outlet 44 extends normal to a general plane P of the shower base 40.

As also shown in Fig. 3 with respect to the third embodiment, internal to the outer wall 46 is a sleeve 20. An upper portion 21 of the sleeve 20 includes an upper flange 22. The upper flange 22 extends generally radially outwardly from the axis A and is adapted to rest on a lower ledge 42 of the base 40 formed by over-moulding the base 40 below and above the flange 22. In effect, the over-moulding forms a radially extending annular groove in which the flange 22 is a snug fit. To further secure the flange 22 in the annular groove, the flange 22 includes an annular rib 23 extending coaxially relative to the axis A, normal to the flange and spaced radially from the axis A. The rib 23 has the form of a short cylindrical wall and strengthens the engagement of the sleeve 20 with the over moulded shower base 40 material.

The flange 22 of the sleeve 20 is trapped in the over-moulded material and resists relative movement in the axial direction relative to the axis A. The rib 23 of the sleeve 20 is trapped in the over-moulded material and resists relative movement of the sleeve 20 in the radial direction relative to the axis A, whereas the trapping of the flange 22 resists movement of the sleeve 20 in the axial direction. The combination of the over moulding of the flange 22 and the rib 23 is to trap the sleeve 20 in the over-moulded material and to resist movement in the axial and radial directions corresponding or relative to the axis A. An upper ledge 24 of the sleeve 20 is provided by an upper surface of the flange 22 and corresponds to a landing of the upper recess 48. The ledge 24 is located in the upper portion 21 region of the cylindrical outlet 44.

The over moulded material forms the lower ledge 42 that supports the flange 22. An upper radially inwardly cantilevered flange 25 extends radially inwardly from the base 40 with which it is uniformly and integrally moulded, over the rib 23 to provide the internal wall 45 defining the upper inward extent of the base 40 about the outlet 44. The attachment 10 includes an externally threaded cylindrical insert 50 that is receivable within the sleeve 20. The insert 50 may be axially moveable within the sleeve 20. The sleeve 20 and the insert 50 are advantageously threadably engageable.

An upper end 52 of the insert 50 may be adapted to receive or engage a grill 60. The grill 60 advantageously includes a grill support 62. The support 62 may be a mounting unit that provides a shoulder for receiving, mounting or resting thereon a grill or grate insert panel 68. The support 62 may further have a downwardly depending skirt 66. The skirt 66 may be adapted to engage an outer periphery of the wall 54 at the upper end 52 of the insert 50.

Optionally, the skirt 66 may also engage the insert upper wall 54. The skirt 66 acts as a female connector within the upper periphery of the wall 54 so that the skirt 66 fits around the external side of the upper wall 54. However, it will be appreciated that this male-female engagement could be reversed so that the skirt 66 fits inside the wall 54. The skirt 66 is, in any case, received within the space in the upper recess 48. Between the underside 63 of the support 62 and the annular wall 45 is an annular gap 70 that is adapted to receive sealant beyond the extent of the covering surface. However, over time, should the seal in the gap 70 deteriorate, leakage through the gap 70 merely feeds into the outlet 44. This provides that, even if there is a failure or leakage in the seal between a shower base 40 covering and the sleeve 20, water can only enter the recess 26a,48 on the inner side of the sleeve 20 to ensure that water does not leak onto the outside of the external cylindrical wall 46 or the area immediately under the base 40. The seal may comprise adhesive, sealant, grouting or another cementing material that seals and/or secures tiles or another surface covering between the shower base 40 and the grill 60. A peripheral wall 64 of the grill support 62 is adapted to extend upwardly beyond part or all of the lower recess 26a and to retain the grill 60.

The grill support 62 is adapted to overhang or extend beyond the footprint of the lower recess 26a defining the outlet r44. The insert 50 is telescopically axially adjustable by virtue of the engagement of the insert 50 with the sleeve 20 by respective internal and external threads 58,28. Therefore, the height of the grill support 62, relative to the shower base 40, can be adjusted to accommodate variable thicknesses of surface covering laid in the space 43, such as tiles or linoleum, and the joins thereof properly sealed against leakage.

In any case, any leakage between the surface material, such as tiles substantially covering the shower base 40 and the grill support 62, is diverted internally of the sleeve 20, that is, into the outlet 44. The water is adapted to feed into an outgoing drainage pipe (not shown) that may be in situ in engagement with the lower most portion 26 of the sleeve 20, but unlike prior art arrangements, the flange 22 ensures that water, even if leaking between the surface covering in the space 43 and the grill support 62, is directed internally of the sleeve 20 and therefore into the drain pipe (not shown) connected to the lower portion 26 of the sleeve 20.

Referring to Fig. 3, the third embodiment of the invention has an attachment 10a which is similar to the attachment 10 shown in Fig. 2. However, the grill plate 68 and grill support 61,62 are circular in plan and part 61 of the grill support is adapted to fit within the footprint of an outlet 44. That is, part of the wall 61 radially extends outside the footprint of the lower recess 26a defined by an inner wall 45 of the shower base 40.

The grill support 62 includes a radially outwardly spaced wall 61 forming part of the grill support 62. The wall 61 radially extends outside the footprint of the lower recess 26a defined by an inner annular wall 45 of the shower base 40 forming the upper mouth of the outlet 44. However, the grill support 62 extends radially outside the footprint of the inner edge of a ledge 24 of the upper portion of the sleeve 20 defining the upper recess 48. The insert 50 is height adjustable whereby to axially position the upper wall 54 telescopically within the downward depending skirt 66 of the grill support 62. The outwardly spaced wall 61 may therefore meet substantially flush the inner surface of the upper end of the mouth of the outlet 44.

The grill support 62 has an outer radial flange 61 that rests on the upper shoulder of the ledge 24 and in the upper recess 48. The skirt 66 engages with the upper wall 54 of the insert 50 at two axially spaced surfaces 65a,b. The surfaces 65a,b are adapted to meet and respectively engage upwardly facing annular edges 55a,b of the insert 50. Therefore the axial spacing of the respective annular edges 55a,b on the one hand and 65a,b on the other, are substantially the same. This ensures the provision of an axial seat with the provision of two axially spaced seating locations for the grill support's 62 location within the upper recess 48, which may also form an effective seal.

The lower and terminal end 27 of the sleeve 20 may be bevelled on its inner and/or outer edges. The bevelled edge of the end 27 may reduce the potential for damage, which may be caused by fraying, wear or fracture at this lower exposed end of the sleeve 20 during transport, storage and/or handling.

The sleeve 20 is supported in the overmoulded encasement of the shower base 40 material by a tapered wall 49 that tapers downwardly and inwardly coaxially with the outlet's 44 axis A. The tapered wall 49 is thicker at its upper portion 49awhere it meets the base body 41 with which it is integrally formed, including moulded. The tapered wall 49 tapers downwardly to a lower edge 49b at which outer surface of the tapered wall converges with the outer surface of the sleeve 20.

Figure 6 shows a fifth embodiment similar to that shown in Fig. 3 with regard to the plan shape of the grill 68. However, the cylinder 44 has an outer tapered wall 49 continuous and integral with the over-moulded base 40 that is similar to that of the fourth embodiment.

Figures 4 and 5 show a fourth embodiment wherein the overhanging grill support 61,62 is rectangular in plan view, as shown in Figs. 1, 2 and 7.

Figure 7 shows a base 40 with an attachment installed according to the first and fourth embodiments shown in Figs. 1, 2, and 4 and 5.

Throughout the specification and claims the word "comprise" and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word "comprise" and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise. In the present specification, terms such as "apparatus", "means", "device" and '"member" may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an "apparatus", "means", "device" or "member" or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where an "apparatus", "assembly", "means", "device" or "member" is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise.

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the outlet 46 extending downwardly. It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention.

Description Ref. Description Ref. Plane of shower base P Axis of outlet A Grill support plane G Attachment 10,10a Insert 50 Cylindrical sleeve 20 51 Upper portion of sleeve 21 Upper end 52 Upper sleeve flange 22 Upper circular edge 53 Vein or rib 23 Upper wall 54 ledge 24 Spaced annular edge 55a Cantilevered flange of base 25 Spaced annular edge 55b Lower most portion of sleeve 26 Lower most portion 56 Terminal end of sleeve 27 57 Internal thread 28 External thread 58 Shower base 40 Grill or grate unit 60 Shower base body 41 Spaced or outward wall 61 Lower ledge 42 Grill support 62 Space for surface covering 43 Outer lip 63 Outlet 44 Outer/peripheral wall of grill 64 support Annular wall of base defining 45 Spaced annular edge 65a recess; Inner wall recess Moulded external cylindrical 46 Spaced annular edge 65a or tapered wall of outlet Lower recess 26a Skirt 66 Upper Recess 48 Internal lip 67 Tapered wall 49 Grill plate/facia/insert panel 68 Upper thicker portion 49a Grate slots 69 and lower thin edge portion of 49b Gap 70 tapered wall

Claims

The claims defining the invention are as follows:

1. A shower base comprising a main body with a broad drainable upper surface and an outlet integrally formed therewith, the outlet comprising an internally threaded and substantially cylindrical sleeve defining a recess including an upper recess that is continuous with a lower recess, the cylindrical sleeve adapted to extend normal to a general horizontal plane of the main body, the outlet including:

the upper recess including an entrance in an upper region of the outlet of the shower base; and

an externally threaded cylindrical insert receivable within the sleeve, the sleeve having a lower portion that defines the lower recess,

wherein:

the insert is:

axially moveable within the sleeve;

adapted to receive a grill support which:

has a downwardly depending skirt engageable with the upper periphery of the insert;

is received within the space defined by the recess;

and

overlaps part or all of the lower recess such that at least part of the grill support extends laterally beyond the footprint of the lower recess;

any leakage between the shower base and the grill support is diverted internally of the sleeve;

the shower base is formed by moulding a shower base material;

the sleeve is over-moulded with the material of the shower base; and the shower base is continuous, and integrally formed, with the sleeve.

2. A shower base as claimed in Claim 1, wherein the shower base and outlet, including the sleeve, are formed from a unitary piece.

3. A shower base as claimed in Claim 1 or 2, wherein the outlet includes a circular ledge at its upper end that corresponds to a landing of the upper recess and defines a recessed space below the grill support.

4. A shower base as claimed in any one of the previous claims, wherein the insert is threadably engaged within the sleeve.

5. A shower base as claimed in any one of the previous claims, wherein the recess is in the form of an annular groove or channel together with the upper periphery in the form of an end wall of the insert.

6. A shower base as claimed in any one of Claims 3 - 5, wherein the circular ledge is formed by an upper surface of a radial flange whereby the radial flange is substantially in the form of a circular disc with a central hole, the circular disc being integrally formed with the wall of the sleeve.

7. A shower base as claimed in any one of Claims 1 - 5, wherein the sleeve includes a full, continuous ring flange at its upper end that extends radially outwardly from a sleeve base wall.

8. A shower base as claimed in Claim 7, wherein the flange is in the form of a full and continuous ring extending around the upper edge of the sleeve with its edge meeting the side or the upper edge of a wall forming part of the sleeve.

9. A shower base as claimed in Claim 7, wherein the flange is overmoulded with the shower base material.

10. A shower base as claimed in Claim 9, wherein the overmoulded shower base material extends down the outer side of the sleeve base wall.

11. A shower base as claimed in Claim 10, wherein the outer wall of the sleeve is unitarily or integrally formed with the main body of the shower base, with the sleeve forming an inner wall or layer of the outlet.

12. A shower base as claimed in any one of Claims 7 - 11, wherein the flange includes an upstanding circular rib or vein extending coaxially around an upper surface of the flange.

13. A shower base as claimed in any one of the previous claims, wherein the grill sits above and spaced from the broad drainable upper surface of the main body so that at least part of the grill support overhangs the outlet or partially extends beyond the footprint of the outlet.

14. A shower base as claimed in Claim 13, wherein the grill support includes a downwardly extending skirt that engages with the outlet.

15. A shower base as claimed in Claim 14, wherein the downwardly extending skirt receives the upper wall of the insert and is mounted thereon, the space continuous with the perforated or slotted grill being in sealed communication with the inner space defined by the insert.