• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Prefabricated shower tray and method of manufacturing thereof, consisting of a pre-assembled piece (1) comprising: coating layer (2) of mosaic, a covering layer-joints (3) of sand, and base layer (4) binder including a structure of rods (5) glued transverse and longitudinally, frame (6) of polished or metallic marble, cement grout (7), protective sealing layer (8) and finishing lacquer layer (9), the base layer being (4) ) of high density expansive polyurethane foam which also includes a fiberglass mesh (16) which is incorporated on a layer of consolidation resin (17) applied on the back of the coating layer (2) and attached to the fragments of it. The polyurethane foam is applied with mold manually or mechanically by injection. (Machine-translation by Google Translate, not legally binding)
    公开号:ES2564427A1
    申请号:ES201431369
    申请日:2014-09-22
    公开日:2016-03-22
    发明作者:Jorge GARCÍA FALCÓ；José Vicente GARCÍA FALCÓ
    申请人:Jorge GARCÍA FALCÓ；José Vicente GARCÍA FALCÓ；
    IPC主号:
    专利说明:

    DESCRIPTION

    Prefabricated shower tray and its manufacturing procedure.

    Object of the invention 5

    The invention, as expressed in the description of the present specification, refers to a prefabricated shower tray and the manufacturing process thereof, providing advantages and features, which will be described in detail below, which represent an improved state alternative. Current technique in its field of application.

    More particularly, the object of the invention is centered on a shower tray of the type whose exposed face is composed of multiple fragments of diverse materials placed as a mosaic and which, consisting of a piece pre-assembled in the workshop instead of in situ 15 and which comprises several layers of different components, each with a specific mission to optimize the union of the assembly, being applied in mold according to a procedure in various steps that will form the finished plate and ready for installation, presents the particularity of counting between said components with a base layer that is made of polyurethane foam and in which it incorporates a reinforcing mesh of 20 fiberglass and a rod structure which allows to reduce the weight of the dish very significantly compared to other similar dishes and the same time give it a very high resistance.

    Field of application of the invention

    The scope of the present invention is part of the industry sector dedicated to the manufacture and installation of sanitary elements, including in particular the field of shower trays.
     30
    Background of the invention

    As is known, a prefabricated shower tray is one that has been manufactured in facilities equipped with the means and materials necessary for its preparation, under technical supervision and using qualified personnel for this purpose, and methodically following the steps established for its manufacture .

    The shower tray that concerns here is of the type that has a mosaic coating and would conventionally be manufactured on site but that, with the components and procedure that distinguish it, is manufactured in the workshop, that is, a plate that groups all the steps that 40 would have to be carried out in the work itself, thus avoiding having to carry out the shower tray on site, so that all the inconvenience that this entails is avoided and, in addition, savings in costs of realization are saved.

    For this, the shower tray chosen by the client is prepared at the factory, with the desired sizes, shapes and colors, and is delivered already finished and ready for installation. Thus avoiding having to make expensive preparations, anti-leakage treatments, wasted time, and achieving the aforementioned economic savings.

    Basically these types of shower trays are composed of numerous pieces of 50 mosaic-like cladding with different materials such as, aged marble,
    boulders, ceramics, treated glass, gresite etc ... that will be placed in a mold designed to house the desired composition in an orderly manner, either forming interlocking, linear drawings, creating borders or aesthetically decorative forms.

    As a reference to the state of the art, it is worth mentioning that the applicant himself is the holder of a patent application for a plate of the type that concerns here, which, although it satisfactorily fulfills the objective of avoiding its realization, leaving it ready to be assembled by means of a mold manufacturing process that allows its pre-assembly, that is, it is a prefabricated piece, it presents certain aspects that can be improved, especially the weight of its base layer 10 made of cement, being The objective of the present invention is the development of a new type of prefabricated shower tray that has been perfected in the composition of its layers to replace the aforementioned consolidating mortar base layer that gives it strength and brings together all its components, which makes It has a lot of weight, for a base layer that is made of polyurethane foam and is reinforced with fiberglass and 15 silicate rods, which makes it much lighter without losing resistance.

    Explanation of the invention.

    The prefabricated shower tray and the manufacturing process thereof that the present invention proposes are thus configured as a novelty within its field of application, since according to its implementation and in a restrictive manner, the objectives are satisfactorily achieved. noted above, the distinguishing details being conveniently set forth in the final claims that accompany the present specification. 25

    Specifically, what the invention proposes is a prefabricated shower tray of the type whose exposed face shows a coating composed of numerous fragments of material arranged as a mosaic, which can be of aged and worn marble, stones with boulders, ceramics , treated glass or glass, gresite or other 30 materials, which are normally placed in an orderly manner according to the desired composition that can be interwoven, linear drawings, creating decorative borders or shapes, etc., said plate being constituted by a series of layers of different materials that, when joined, make up the mentioned piece, comprising more specifically the following elements:

    - A layer of said coating that forms the visible face of the plate and which, as mentioned, is formed by multiple fragments of various materials, arranged in a decorative manner and in order to obtain a surface suitable for barefoot tread, and that It will have the essential role of the dish, since it forms a large part of the decoration and quality of the manufactured model.

    - A layer covers sand joints. It consists of a layer of silica sand, of fine granulometry, which is basically applied to cover the joints or gap that may be left between the fragments of the cladding mosaic, having as mission 45 to prevent said fragments from presenting movements to each other and, at the same time, serve as a barrier to avoid that the consolidation resin applied, as indicated below, can transfer to the exposed face of the shower tray causing uncomfortable remains very difficult to clean.
    - A layer of consolidation resin that, applied on the back of the coating layer and glued to the stone or material fragments that make up the layer, is intended to seal and reinforce the entire composition.

    - A fiberglass reinforcement mesh, whose function is to bind together with the polyurethane foam mentioned below, being embedded in said foam and providing even more rigidity to the entire assembly.

    - A structure of silicate bonding rods. Hard, rigid and flexural resistant material .. These rods are glued on the surface of the mosaic, longitudinally and 10 transversely, contributing to give the shower tray greater rigidity, thus avoiding great part of the flexion, and having as a fundamental mission to link in the form of a framework with the polyurethane foam, forming a body of great resistance, these rods will be the fundamental element to guarantee its resistance to handling, vibrations, temperature changes, transport and placement. fifteen

    - A layer of expansive polyurethane foam of high density and great adhesive power, which will be the base or main binder layer responsible for consolidating the mosaic on the back side. Once this foam layer is applied and consolidated, it will form, together with the fiberglass mesh and tie rods, a monobloc, rigid, compact and high-strength assembly. Thanks to this layer of polyurethane foam, the total weight of the shower tray can be reduced considerably compared to those made with cement base and at the same time a very high resistance is also obtained.
     25
    - A frame, of polished or metallic marble, with a termination of blunt edges that has the mission of perimetering the piece and, where appropriate, supporting a screen, avoiding leaks and splashes of water when using the shower. This frame is glued and sealed with polymer silicone to the piece formed by the coating and the foam layer with the fiberglass mesh and the rod structure. 30

    - A layer of colored cement, for grouting the mosaic, to fill the joints of the fragments that form the coating layer, fulfilling an aesthetic and reinforcing function thereof.
     35
    - A layer of epoxy resin filling, hermetic and transparent, which has the mission of treating the exposed face of the shower tray as a protective layer that preserves the mosaic used in the coating layer of contact with water, soaps and Cleaning products.
     40
    -And a layer of finishing lacquer, consisting of a textured polyethylene resin, to give the plate a finished, shiny and non-slip appearance.

    As noted in previous sections, the described polyurethane foam base layer, together with the fiberglass mesh and the fact that the rods are made of silicate, constitute the essential innovation elements of the present invention, as well as the incorporation of the consolidation resin layer that sticks under the segments that form the mosaic of the coating. This resin layer, although applied in the preferred embodiment of the invention, does not imply a limitation.
     fifty
    For its part, the manufacturing process of the shower tray includes the following steps:

    - Have a prefabricated and reusable mold with the shapes and measures of the shower tray to be made. This mold is provided with mechanical seals for the top cover to ensure its tightness. Optionally, it is provided with several injector ducts through which the polyurethane foam will pass under the pressure and in the amount necessary to make the desired shower tray model, in case the polyurethane foam is applied mechanically. In any case, the mold allows the possibility of the polyurethane foam to be applied manually, that is, by lifting the closing lid, applying the necessary amount of product and closing, leaving the product to act and opening the closing lid a Once the necessary setting time has elapsed.

    - Place on the mold in an orderly manner, the pieces of the mosaic that make up the lining layer and that will be the visible face of the shower tray to be made.

    - Glue with resin a rigid piece of silicate of 20 x 20 x 1 centimeters in the place where the drain valve will go, in order to reinforce the thinnest area of the shower tray and provide at the same time a flat and rigid base for the rear seat 20 of the drain valve. This piece is flush with the back side of the shower tray.

    - Apply homogeneously the layer of fine-grained silica sand covering the joints between the fragments of the coating and remove the surplus of sand that does not admit said joints, this sand also has the mission of preventing the resin from penetrating the face of the mosaic.

    - Then apply the consolidation resin layer over the entire surface, that is, on the back side of the coating. And, before this resin sets, glue the fiberglass reinforcement mesh on it, for which a piece of this material is cut, with the measurements of the shower tray to be made, placing it on top of the mosaic and covering all the surface, and on said mesh the silicate reinforcing rods, disposing them longitudinally and transversely, in order to create ribs that provide greater rigidity to the shower tray. 35

    - Then apply a thin layer of flint sand on the resin, the mesh and the rods, in order to create a rough surface that provides high adhesion to the polyurethane foam, which is then applied either manually or mechanically by means of an injection pump. 40

    - Apply the polyurethane foam in a liquid state in the amount necessary for each plate model according to its size, with the tie rods and the reinforcement mesh embedded in it so that they provide rigidity and resistance to the piece.
     Four. Five
    - Then close the mold with its lid with mechanical seals. Said foam is composed of two components in equal parts, which once mixed cause an expansive reaction inside the mold, creating volume, adhesion, and solidification of the entire shower tray, after setting. Taking into account that said foam will expand inside a mold, the foam will take the form of said mold 50
    in terms of measurements, any mark that is planned to be incorporated, for example from the manufacturer and / or the model of the shower tray made, is also engraved.

    - After drying the polyurethane foam, open the mold, remove the already consolidated piece, turn it over and make a hole of the appropriate diameter for the water drain valve, at the deepest point of the upper surface with its corresponding recess for the grid housing.

    - On the visible side of the shower tray, glue and seal with polymer silicone to the perimeter of the piece the frame. 10

    - Clean the exposed face of the shower tray, to remove traces of foam that could have passed the mosaic coating, and apply the colored cement layer to the joints of the mosaic pieces. Before its total setting, remove the excess of this grout cement with sponge and plenty of water, until complete removal, to leave only the cement that is embedded between the joints.

    - Once dry apply the layer of epoxy resin filling, to close all possible existing pores, consolidate the plate further and achieve its full sealing.
     twenty
    - Once the epoxy resin dries, apply the two-component and textured transparent polyurethane resin layer.

    - Finally, on the back of the shower tray, glue a sealing gasket, consisting of a circular piece of rubber, on the reinforcement silicate piece 25 previously incorporated around the hole made for the drain, so that the corresponding siphon , have a seat in said rubber to obtain a total sealing thus avoiding water leaks.

    The shower tray is finished, completely waterproof and ready for packaging. 30

    According to the above, it is found that the described prefabricated shower tray and the manufacturing process thereof represent an innovation of structural and constitutive characteristics unknown until now, reasons that together with its practical utility, provide it with sufficient foundation to obtain the exclusivity privilege that is requested.

    Description of the drawings

    To complement the description that is being made and in order to help a better understanding of the characteristics of the invention, this descriptive report is attached, as an integral part thereof, of a set of drawings, in which with Illustrative and non-limiting nature has represented the following:

    Figure number 1.- Shows a schematic top plan view of an example of an embodiment of the prefabricated shower tray, object of the invention, its general external configuration being appreciated from its visible face.


    Figure number 2.- Shows a schematic bottom plan view of the example of the shower tray, according to the invention, shown in Figure 1, which has been shown
    partially sectioned to show the fiberglass mesh and rod structure that are embedded in the base layer of polyethylene foam.

    Figure number 3.- Shows a schematic elevation view of the example of the shower tray, according to the invention, shown in Figures 1 and 2, also shown partially sectioned and in this case showing its coupling to the drain siphon.

    Figure number 4.- Shows an enlarged view of the detail A indicated in figure 3, showing more clearly each of the different layers that form the shower tray piece, some of which have been exaggerated in proportion to allow 10 A better observation of them.

    Figure number 5.- Shows an elevation and sectional view of an example of the mold used in the manufacturing process of the shower tray, showing the possibility that the foam can be applied mechanically by injection. fifteen

    Preferred Embodiment of the Invention

    In view of the aforementioned figures, and according to the numbering adopted, a preferred but not limiting example of the recommended shower tray 20 can be observed, which comprises the parts and elements that are indicated and described in detail then.

    Thus, as seen in these figures, the prefabricated plate in question is a piece
    (1) pre-assembled in workshop comprising, essentially: 25

    - A coating layer (2), formed by multiple fragments of various materials, arranged decoratively as a mosaic.

    - A layer covers joints (3) of silica sand, of fine grain size, covering the joints 30 or gaps between the fragments of the cladding mosaic (2).

    - And a base layer (4) which acts as a binder including a structure of rods (5) bonded together with resin and distributed transversely and longitudinally under the fragments of the coating (2), with the particularity that said base layer (4) It is made of 35 high density expansive polyurethane foam in which, in addition, a fiberglass mesh (16) is also included.

    It should be noted that, in the preferred embodiment of the invention, the fiberglass mesh (16) is incorporated (when the piece is upside down in the mold) onto a layer of consolidation resin 40 (17) applied by the back of the coating layer and glued to the fragments thereof, and on said mesh the rod structure (5) is incorporated, with mesh and rods embedded in the base layer (4) of polyethylene foam.

    The piece is finished off with a frame (6), of polished or metallic marble, glued and sealed with polymer silicone to the perimeter edge of the piece (1).

    In addition, the piece has a layer of grouting cement (7) of the same color as the fragments of the cladding mosaic (2), and that fills all existing joints between said fragments and with the frame (6), from the exposed face from the dish. fifty
    - A protective hermetic layer (8), made of transparent polyester resin, which covers the central part (1a) and the frame (6) by its visible face.

    - And a finishing lacquer layer (9) of two-component textured resin, which covers the protective layer (8) on the face of the plate and provides a shiny and non-slip 5 finish.

    In accordance with Figure 5, an example of the mold (10) that is used in the manufacturing process of the piece (1) is observed, showing the hermetic cover (10a) that it has and the lateral machined closures (10b), to close said cover after the application of the expansive foam, as well as the optional incorporation of the system of injector ducts (10c) connected to a pump (10d) to drive the foam under pressure. The arrows of these ducts (10c) indicate the path of the foam driven by the pump into the mold.
     fifteen
    Furthermore, in said figure it can also be seen how in said mold (10) the fragments of the coating layer (2) are incorporated first and on them, together with the other components that are not appreciated, the base layer (4) which forms a polyurethane foam, so that the exposed face of said coating (2) is located inferiorly. twenty

    On the other hand, in figure 3 it is observed how the mentioned piece (1) pre-assembled in the workshop, is ready for its placement and connection to the drain siphon (11), incorporating the reinforcement piece (12) and the sealing gasket ( 13) in the hole (14) made for this purpose (which are best seen in Figure 2), with a recess at the top to include a grid (15) (Figure 1), avoiding all the inconveniences of the embodiment in work that until now require shower trays made with coating of mosaic pieces and that, thanks to the base layer (4) of polyurethane foam with the fiberglass mesh (15) and the rod structure (5), which are preferably made of silicate, it constitutes a light and very resistant element. 30

    Describing sufficiently the nature of the present invention, as well as the way of putting it into practice, it is not considered necessary to make its explanation more extensive so that any person skilled in the art understands its scope and the advantages that derive from it, stating that, within its essentiality, it may be put into practice in other embodiments that differ in detail from that indicated by way of example, and to which it will also achieve the protection that is sought as long as it does not alter, change or modify its principle fundamental.
    权利要求:
    Claims (7)
    [1]

    1. Prefabricated shower tray, consisting of a piece (1) pre-assembled in the workshop and ready for installation and connection to the drain trap (11), which comprises a coating layer (2), formed by multiple fragments of various materials, arranged in a decorative manner as a mosaic, a layer covers joints (3) of fine sand, which covers the joints or gaps between the fragments of the cladding mosaic (2) and a base layer (4) that acts as a binder including a structure of rods (5) glued together transversely and longitudinally under the fragments of the cladding (2), and which is finished off with a perimeter frame (6) of polished or metallic marble, with a 10 layer of grouting cement (7) that It fills all of the lining (2) by the exposed side of the plate, protective sealing layer (8) and a finishing lacquer layer (9), characterized in that said base layer (4) is made of high density expansive polyurethane foam.
      fifteen
    [2]
    2. Prefabricated shower tray, according to claim 1, characterized in that a fiberglass mesh (16) is also included after the coating layer embedded in the base layer (4) of polyurethane foam.

    [3]
    3. Prefabricated shower tray according to claim 2, characterized in that the fiberglass mesh 20 (16) is incorporated on a layer of consolidation resin (17) applied on the back of the coating layer (2) and glued to the fragments of it.

    [4]
    4. Prefabricated shower tray according to any of claims 1-3, characterized in that the rods of the rod structure (5) are made of silicate.

    [5]
    5. Method of manufacturing a shower tray according to the one described in claim 4, which is carried out in the workshop using a prefabricated and reusable mold with the shapes and measures of the shower tray to be carried out, where firstly they are placed neatly The mosaic pieces that make up the cladding layer (2) and then the layer covers joints (3) of fine sand, is characterized by comprising the following steps:
    - Then apply the consolidation resin layer (17) over the entire rear surface of the coating. And, before this resin sets, glue on it the fiberglass reinforcement mesh (16) and on said mesh the silicate reinforcing rods (5).
    - Then apply on the resin, the mesh and the rods, as a dusting, a thin layer of flint sand, to create a rough surface. 40
    - Apply the polyurethane foam in a liquid state in the amount necessary for each plate model according to its size, with the tie rods and the reinforcement mesh embedded in it so that they provide rigidity and resistance to the piece.
     Four. Five
    - Close the mold with its hermetic lid and mechanical seals.
    - After drying the polyurethane foam, open the mold, remove the consolidated part, turn it over and make a hole of the appropriate diameter for the water drain valve, at the deepest point of the upper surface with a recess for 50 grid housing, and apply the rest of the surface layers.
    [6]
    6. Manufacturing method according to claim 5, characterized in that the polyurethane foam is applied manually, lifting the lid (10a) from the mold, applying the necessary amount of product and closing with the mechanical closures (10b).

    [7]
    7. Manufacturing method according to claim 5, characterized in that the polyurethane foam is mechanically applied with a mold (10) which is provided with several injector ducts (10c) through which the polyurethane foam will pass under pressure driven by a pump (10d).
     10
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    同族专利:
    公开号 | 公开日
    ES2564427B1|2017-01-09|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US2836839A|1956-06-05|1958-06-03|Julian John|Fountain toothbrush|
    GB2440719A|2006-08-08|2008-02-13|Aqess Co Ltd|Shower tray|
    FR2985450A1|2012-01-10|2013-07-12|Morais Ricardo Pereira|Device for manufacturing receiver of flat shower material from mosaic tile, has mold that is utilized for installation of set of materials, and binder that is casted to obtain mosaic tile that has all characteristics of receiver of shower|CN109008734A|2018-08-31|2018-12-18|宁波联城住工科技有限公司|Box bathroom chassis and its manufacturing method|
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