METHOD OF MANUFACTURING A DRAINAGE BASE TRAY FOR A SHOWER, AND SHOWER DRAINAGE BASE TRAY RESULTING THEREFROM

Abstract

A method of manufacturing a drainage base tray for a shower, the method including the steps of: a) providing a foldable sheet of metallic material; b) cutting a one-piece blank from the foldable sheet of metallic material; c) folding the blank along at least one folding line in order to define at least one corresponding slope within the blank, the slope having an upper portion and a bottom portion defining a sloping gradient; and d) providing the blank with a draining hole adjacent to the at least one folding line and in proximity of the bottom portion of the slope, for allowing waste liquid to drain via the draining hole of the drainage base tray. Also described is a resulting shower drainage base tray, and a one-piece blank made of metallic foldable material and having portions for manufacturing the shower drainage base tray. The present system also concerns a shower drainage kit including a grill component positioned, shaped and sized for placement over the shower drainage tray.

Description

FIELD OF THE INVENTION

The present invention relates to a method of manufacturing a drainage base tray. More particularly, the present invention relates to a method of manufacturing a drainage base tray for a shower, and also relates to a shower drainage base tray resulting from the method, and to a corresponding one-piece blank used for manufacturing the shower drainage base tray, and also relates to a corresponding kit including the same. The present application claims the priority of CA patent application No. 2,929,761 dated May 10, 2016, the content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Drainage base trays used for showers are well known in the art.

For example, known to the Applicant are the following Us patents and patent applications: U.S. Pat. Nos. 3,757,358; 4,541,132; 4,557,004; 6,003,169; 6,990,695 8,677,521; 8,856,980; 2001/0052148; 2004/0205890; 2011/0088160; 2012/272449; and 2015/0067961.

Also known to the Applicant are the following documents: EP 1378197; EP 1916932; EP 2036476; DE 19723153; DE 19725963; DE 202004013374; DE 102006007471; DE 202016002387; and FR 2949312.

It is also known in the art that drainage base trays (e.g. linear drain) actually available on the market present numerous drawbacks.

The first drawback concerns manufacturing processes for drainage base tray. In the case of linear drain, and depending on the product, several transformations are necessary, which generate important costs. For instance, the manufacturing process of shower bases ready for the tiling step available on the market usually requires the use of specialized machinery, such as injection moldings. Such shower bases are typically made of plastic and do not offer the possibility to add a decorative grid. Some linear drains comprise stainless steel, but they typically require in their manufacturing processes several steps of welding and folding with mitigated results. The manufacturing process is also known to consume a significant amount of energy.

The second drawback relates to the complexity of the installation process of the drainage base tray. The installer often faces uncertainty during the installation process, which may result in a poorly sealed system. For at least this reason, errors occurring during the installation process involve high costs and time delay. Furthermore, the systems currently available on the market are generally not suitable for combining the shower base with a decorative drain, which affects not solely the draining property of the drainage base tray linear drain, but also the sealing of the entire system. When the consumer is not satisfied with the decorative grid, one is forced to destroy the shower tray to change it.

The third drawback concerns the environmental impact generated by this type of system as currently found on the market. The products offered on the market typically include plastic-based materials, polymer-based and hybrid fiber requiring a lot of processing during their manufacturing steps. These products are often not recyclable.

Thus, it would be particularly useful to be able to provide an improved system which, by virtue of its design and components, would be able to overcome or at least minimize some of the known drawbacks associated with conventional systems.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a device which, by virtue of its design and components, is intended to satisfy the above-mentioned need and which is thus an improvement over other related conventional drainage base tray device, systems, assemblies and/or manufacturing methods.

In accordance with the present invention, the above main object is achieved, as will be easily understood, with manufacturing method such as the one briefly described herein and such as the one exemplified in the accompanying drawings.

More particularly, according to one aspect of the present invention, there is provided a method of manufacturing a drainage base tray for a shower, the method comprising the steps of:

• • a) providing a foldable sheet of metallic material;
  • b) cutting a one-piece blank from the foldable sheet of metallic material;
  • c) folding the blank along at least one folding line in order to define at least one corresponding slope within the blank, the slope having an upper portion and a bottom portion defining a sloping gradient; and
  • d) providing the blank with a draining hole adjacent to the at least one folding line and in proximity of the bottom portion of the slope, for allowing waste liquid to drain via said draining hole of the drainage base tray.

As will be easily understood by a person skilled in the art, step a) and b) could simple be replaced by a single step of providing a plurality of pre-cut a one-piece blanks made of foldable sheet of metallic material, each one of these blanks being

According to another aspect of the present invention, there is also provided a one-piece blank made of metallic foldable material and having portions such as the ones described herein and/or illustrated in the accompanying drawings for manufacturing the shower drainage base tray.

According to another aspect of the present invention, there is also provided a shower drainage base tray resulting from the above-mentioned blank and/or method.

According to another aspect of the present invention, there is also provided a shower drainage kit for use with a shower, the drainage kit comprising: i) a shower drainage base tray such as the one described and/or illustrated in the present description; and ii) a grill component positioned, shaped and sized for placement over said shower drainage tray.

According to another aspect of the present invention, there is provided a system, a station and/or a machine for carrying out the above-mentioned method.

According to another aspect of the present invention, there is provided a processing plant provided with the above-mentioned system, station, machine and/or components thereof.

According to another aspect of the present invention, there is provided a kit with corresponding components for assembling the above-mentioned device, system, station, machine, processing plant and/or components thereof.

According to yet another aspect of the present invention, there is also provided a set of components for interchanging with components of the above-mentioned kit.

According to yet another aspect of the present invention, there is also provided a method of assembling components of the above-mentioned kit and/or set.

According to yet another aspect of the present invention, there is also provided a method of doing business with the above-mentioned method(s), kit, set, device, system, station, machine, processing plant and/or components thereof.

According to yet another aspect of the present invention, there is also provided a product (ex. blank, sheet of material, etc.) having been obtained or processed (modified, altered, etc.) with the above-mentioned method(s), kit, device, system, station, machine, processing plant and/or components thereof.

The objects, advantages and other features of the present invention will become more apparent upon reading of the following non-restrictive description of preferred embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a shower drainage base tray according to a possible embodiment of the present system.

FIG. 2 is a perspective view of a shower drainage base tray according to another possible embodiment of the present system.

FIG. 3 is a perspective view of a shower drainage base tray according to another possible embodiment of the present system.

FIG. 4 is a perspective view of a shower drainage base tray according to another possible embodiment of the present system.

FIG. 5 is a perspective view of a decorative grid according to a possible embodiment of the present system.

FIG. 6 is a perspective view of a shower drainage base tray and a decorative grid according to a possible embodiment of the present system.

FIG. 7 is a perspective view of a shower drainage base tray comprising a decorative grid according to another possible embodiment of the present system.

FIGS. 8A and 8B are perspective views of portions of shower drainage base tray according to possible embodiments of the present system.

FIGS. 9A and 9B is a perspective view of a shower drainage base tray according to possible embodiments of the present system.

FIGS. 10A and 10B are perspective views of a shower drainage base tray according to possible embodiments of the present system.

FIG. 11 is a perspective view of an assembled shower drainage base tray according to another possible embodiment of the present system.

FIG. 12 is a perspective view of an assembled shower drainage base tray according to another possible embodiment of the present system.

FIG. 13 is a top view of the assembled shower drainage base tray shown in FIG. 12.

FIG. 14 is a cross-sectional view taken along line XIV-XIV of FIG. 13.

FIG. 15 is a cross-sectional view taken along line XV-XV of FIG. 13.

FIG. 16 is a rear view of the assembled shower drainage base tray shown in FIG. 12.

FIG. 17 is a side view of the assembled shower drainage base tray shown in FIG. 12.

FIG. 18 is a top view of an unassembled shower drainage base tray according to another possible embodiment of the present system.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

In the following description, the same numerical references refer to similar elements. Furthermore, for sake of simplicity and clarity, namely so as to not unduly burden the figures with several reference numbers, only some figures have been provided with reference numbers, and components and features of the present invention illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions (expressed in inches, for example) shown in the figures are preferred, for exemplification purposes only.

Moreover, although the present invention was primarily designed to be used as a shower drainage base tray for draining waste liquid (ex. greywater, etc.) from a shower, it may be used with other types of objects, and in other fields, as apparent to a person skilled in the art. For this reason, expressions such as “shower”, “drainage”, “base”, “tray”, “draining”, “waste liquid”, “greywater”, etc., used herein should not be taken as to limit the scope of the present invention and includes all other kinds of objects or fields with which the present invention could be used and may be useful, as apparent to a person skilled in the art.

Moreover, in the context of the present invention, the expressions “base”, “tray”, “device”, “system”, “method”, “kit”, “assembly”, and “product” as well as any other equivalent expressions and/or compounds word thereof known in the art will be used interchangeably, as apparent to a person skilled in the art. This applies also for any other mutually equivalent expressions, such as, for example: a) “drainage”, “draining”, etc.; b) “folding”, “bending”, etc.; c) “pan(s)”, “tray(s)”, “base”, etc.; d) “grid”, “decorative grid”, “grid”; as well as for any other mutually equivalent expressions, pertaining to the aforementioned expressions and/or to any other structural and/or functional aspects of the present invention, as also apparent to a person skilled in the art.

Furthermore, in the context of the present description, it will be considered that all elongated objects will have an implicit “longitudinal axis” or “centerline”, such as the longitudinal axis of an elongated sheet, or the centerline of a hole, for example (and as a result, there is a “transversal axis” being substantially “perpendicular” for each longitudinal axis, etc.), and that expressions such as “connected” and “connectable”, or “mounted” and “mountable”, may be interchangeable, in that the present invention also relates to a kit with corresponding components for assembling a resulting fully assembled and operational shower drainage base tray (and/or kit including the same).

Moreover, components of the machine(s) and/or steps of the method(s) described herein could be modified, simplified, altered, omitted and/or interchanged, without departing from the scope of the present invention, depending on the particular applications which the present invention is intended for, and the desired end results, as briefly exemplified herein and as also apparent to a person skilled in the art.

In addition, although the preferred embodiment of the present invention as illustrated in the accompanying drawings may comprise various components, and although the preferred embodiments of the stripping method and corresponding stripping device may consist of certain preferred steps and components as explained herein, not all of these steps and components are essential to the invention and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present invention. It is to be understood, as also apparent to a person skilled in the art, that other suitable steps, components and cooperation thereinbetween, may be used for the present method and corresponding device (as well as corresponding components) according to the present invention, as will be briefly explained hereinafter and as can be easily inferred herefrom by a person skilled in the art, without departing from the scope of the present invention.

List of Numerical References for Some of the Corresponding Possible Components Illustrated in the Accompanying Drawings

1. drainage base tray

3. foldable sheet

5. one-piece blank

7. folding line (for creating slope(s) of the drainage base tray)

7a. first folding line

7b. second folding line

7c. third folding line

7d. fourth folding line

9. slope (for evacuating waste liquid)

9a. first slope

9b. second slope

9c. third slope

9d. fourth slope

11. folding line (for creating sidewall or curb about the drainage base tray)

11a. folding line for 1^st bent (ex. at an angle θ₁ of about 90.00°)

11b. folding line for 2^nd bent (ex. at an angle θ₂ of about 45.00°)

11c. folding line for 3^rd bent (ex. at an angle θ₃ of about 92.05°)

11d. folding line for 4^th bent (ex. at an angle θ₄ of about 87.95°)

11e. folding line for 5^th bent (ex. at an angle θ₅ of about 90.00°)

13. draining hole

15. recessed contour form (about the draining hole)

17. sidewall (of drainage base tray)

19. portion (of blank for folding into side wall of curb)

21. curb (of drainage base tray)

23. surface coating and/or texturing

25. grill component (to be used with drainage base tray)

27. drainage holes (of grill component)

29. flag

Broadly described, the present invention, as illustrated in the accompanying drawings, relates to a method of manufacturing a drainage base tray for a shower, the method comprising the steps of: a) providing a foldable sheet of metallic material; b) cutting a one-piece blank from the foldable sheet of metallic material; c) folding the blank along at least one folding line to define at least one corresponding slope within the blank, the slope having an upper portion and a bottom portion defining a sloping gradient; and d) providing the blank with a draining hole adjacent to the at least one folding line and in proximity of the bottom portion of the slope, for allowing waste liquid to drain via said draining hole of the drainage base tray.

Step a) may comprise the step of providing a foldable sheet of stainless steel, although other suitable and/or corrosion-resistant materials could be used as long as they enable a folding therefor. As it will be understood, step a) could alternatively comprise the step of providing a foldable sheet of any material that can be plastically-deformed and remain as such once folded, deformed and/or bended. For example, and without being limitative, the foldable sheet could be formed from plastic, thermoplastic (e.g. acrylic), polymer, metal (e.g. aluminum), brass, combinations thereof or any other material having the structural and physical properties allowing the foldable sheet to be folded according to the method defined in the present description.

According to one possible embodiment, step a) may comprise the step of providing at least one roll of foldable sheet of metallic material. As it will be readily understood, the step of providing at least one roll of foldable sheet is not necessarily limited to providing a foldable sheet of metallic material, but could also comprise the step of providing at least one roll of the foldable and/or plastically-deformable materials that have been previously listed. Alternatively, step a) could comprise the step of providing a plurality of foldable sheets of metallic material (ex. stacks of different and/or same sheets, etc.) and/plastic-deformable materials listed in the present description.

In regards to step b), it may comprise the step of cutting a one-piece blank along a predetermined pattern. This can be done using a machining tool selected from the group consisting of a punching machine, a computer-numerical-control (CNC) machine and a jigsaw. Optionally, the predetermined pattern can be traced and/or physically marked and/or indicated on a surface of the foldable sheet with marking means and/or using a template of a given shape. For example, and without being limitative, the template could have selected dimensions, shape and/or profile allowing to guide one of the previously listed machining tools during the cutting step of the one-piece blank from the foldable sheet. Alternatively, the predetermined pattern could be traced and/or indicated with a pen, a laser, an engraving, an etching, a print, a carving, a laser, an illumining device, a projection, combinations thereof, or any other means, methods and/or devices known by one skilled in the art and allowing to indicate where to cut the one-piece blank along the predetermined pattern.

In regards to step c), it may comprise the step of folding the blank along at least one folding line using a corresponding press. As can be easily understood from the accompanying drawings, folding the blank could be done along n folding lines, so as to define n corresponding slopes within the blank, where n is an integer greater than 1 (see FIG. 1, for example). Alternatively, folding of the blank could be done along n folding lines, so as as to define n+1 corresponding slopes within the blank. Yet optionally also, step c) may comprises the step of folding the blank along n folding lines, so as as to define 2n corresponding slopes within the blank, where n is an integer greater than 1.

According to one possible embodiment, step c) may comprise the step of predetermining a height of the sloping gradient of the foldable sheet to condition evacuation rate of waste liquid from the single foldable sheet towards the drainage hole. As shown in the accompanying drawings, the height of the sloping gradient can typically range from about ⅜ to ½ inches. It will readily be understood that this range serves an illustrative purpose only, and could of course be different, with respect with one's need(s).

According to one possible embodiment, step c) may comprise the step of applying a force to the foldable sheet along at least a portion of the least one folding line to form the sloping gradient, the force being applied until a top portion of the foldable sheet reaches a corresponding depth of the drainage hole. For example and without being limitative, the force could be applied with a corresponding press having a substantially V-shaped head receivable into a complementary bottom portion. Optionally, the force can be applied along an entirety of the at least one folding line. It will be understood that the step of applying a force can be carried out in one or more steps according to the need(s) of one skilled in the art. For example, the step of applying a force could be repeated several times and the magnitude of the force could be incrementally increased from one repetition to another, so as to allow a more progressive folding of the foldable sheet and/or a better control of the folding step.

According to one possible embodiment, step c) may comprise the step of indicating a position of the at least one folding line onto the one-piece blank with a marking means selected from the group consisting of a pen, a laser, an engraving, an etching, a print, a carving, a laser, an illumining device and a projection. As it will be readily understood, the marking means comprise but are not limited to methods and/or means of physically, superficially and/or temporarily/permanently marking the one-piece blank so as to indicate the position of the at least one folding line.

According to one possible embodiment, step c) may be carried out using a computer-numerical-control (CNC) machine. Alternatively, and as it will be readily understood by one skilled in the art, step c) could also be carried out using a hydraulic press, mechanical press or any other press tools allowing to fold the blank along the folding lines. As it will be understood, the step c) could also be carried out using other mechanical and/or manual and/or automated means, depending on the properties of the material to be folded, but also according to one's need(s).

In regards to step d), it may comprise the step of selecting a depth of the drainage hole. As illustrated in the accompanying drawings, the depth could correspond to a distance between a top portion of the foldable sheet and a top portion of the drainage hole. Alternatively, it could also be possible to define the depth as the distance between the top portion or any other portion of the foldable sheet and a given reference point of/located in the drainage hole.

According to one possible embodiment, step d) may be carried out using a machining tool selected from, without being limited to the group consisting of a punching machine, a computer-numerical-control (CNC) machine and a jigsaw. Alternatively, step d) could also be carried out using laser cut, plasma, drilling, turning, burning, water jet or any other means, tools and/or methods know by one skilled in the art.

According to one possible embodiment, step d) may further comprise the step of providing the draining hole with a corresponding recessed contour form. Alternatively, the step of providing the draining hole with a corresponding recessed contour form includes the step of cross-breaking the foldable sheet. Yet optionally, the step of providing the draining hole with a corresponding recessed contour may include the step of punching the drainage hole with a punch tooling having a punch and a die. For example, and without being limitative, the punch can have a substantially cylindrical profile engageable with a complementary bottom portion of the die. As it will be readily understood, the punch can have a shape that fits one's needs. Accordingly, the punch can have a substantially square, spherical, ovoidal, regular/irregular polygonal or custom profile.

According to one possible embodiment, the step of providing the draining hole with a corresponding recessed contour form may include the step of machining the draining hole. The step of machining the drainage hole can be carried out using a machining tool selected from, but not limited to the group consisting of a drill, a punching machine, a computer-numerical-control (CNC) machine and a jigsaw. It will be understood that the step of providing the draining hole with a corresponding recessed contour form may alternatively be carried out using any machining tool and/or methods allowing to form a recessed contour, such as abrasive flow machining, abrasive jet machining, cutting, milling, automatic lathe, shear, guillotine, shaper, combination(s) thereof or any other tools, methods and means known by one skilled in the art.

According to one possible embodiment, at least one of steps b), c) and d) of the method may be carried out using a corresponding press. Optionally, plurality of steps b), c) and d) of the method could be carried out using a same corresponding press. For example, and without being limitative, all of steps b), c) and d) of the method can be carried out using a same corresponding press.

In some embodiments, the method may further comprise the step of e) folding a peripheral portion of the blank for providing the shower drainage base tray with at least one corresponding sidewall being positioned, shaped and sized for containing waster liquid within the shower drainage tray. Optionally, the at least one sidewall could be particularly useful to abut a shower wall during the installation of the drainage base tray as described in the present description.

According to one possible embodiment, the at one corresponding sidewall may be defined by at least one fold of a corresponding portion of the one-piece blank. Alternatively, the at one corresponding sidewall can defined by a plurality of folds of corresponding portions of the one-piece blank.

According to one possible embodiment, step e) may comprise the step of folding n peripheral portions of the blank, so as as to define n corresponding sidewalls about the shower drainage base tray, where n is an integer greater than 1. For example, and without being limitative, in the case of a substantially rectangular drainage base tray as disclosed in some of the accompanying drawings, the folding step could include folding 2, 3 or 4 peripheral portions of the blank so as to define 2, 3 or 4 corresponding sidewalls.

According to one possible embodiment, step e) may comprise the step of folding a peripheral portion of the blank so as to define at least one corresponding open-ended sidewall. Optionally, step e) could comprise the step of folding a peripheral portion of the blank so as to define at least one corresponding open-ended sidewall having a substantially U-shaped cross-sectional profile. Alternatively, the step of folding a peripheral portion of the plane could be carried out so as to define at least one sidewall having, for example: a substantially O-shaped, T-shape, V-shaped, L-shaped, S-shaped, J-shaped, C-shaped, Z-shaped, or any other shape, in correspondence with the requirements and/or specific needs and preferences of one skilled in the art.

According to one possible embodiment, step e) may comprise the step of folding a peripheral portion of the blank so as to define at least one corresponding closed-ended sidewall. Optionally, step e) could comprise the step of folding a peripheral portion of the blank so as to define at least one corresponding closed-ended sidewall having a substantially rectangular cross-sectional profile.

According to one possible embodiment, step e) may comprise bending at about 90 degrees at least one corresponding peripheral edge of the foldable sheet. As a result, the corresponding peripheral edge could for example extend substantially perpendicularly from the drainage base tray. Alternatively, the bending step could be carried out so as to form a predetermined angle and facilitate a further installation of the drainage base tray in a shower area. For example, and without being limitative, the predetermined angle could be slightly acute or slightly obtuse.

According to one possible embodiment, step e) could comprise the step of guiding the foldable sheet during bending of the at least one sidewall. For example and without being limitative, the step of guiding the foldable sheet could comprise engaging a guiding mechanism to maintain the foldable sheet in position during bending of the at least one sidewall. It will be understood that the step of guiding the foldable sheet aims at maintaining the foldable sheet during its bending and so as to limit its movement, hence allowing clean sheet folding and better reproducibility of the folding step from one drainage base tray to another. It will be understood that the step of guiding the foldable sheet can be carried out manually and/or automatically by an operator, a blank holder, other mechanical devices, a robot, a motor, combinations thereof, or any other devices and methods allowing to guide the foldable sheet during its bending.

According to one possible embodiment, step e) may further comprises the step of sealing a plurality of sidewalls of the drainage base tray. The step e) can optionally further comprise the step of reinforcing a plurality of sidewalls of the drainage base tray. Alternatively, the step of reinforcing a plurality of sidewalls can comprise the step of welding the plurality of sidewalls with one another. The step of reinforcing a plurality of sidewalls could for example be carried out using a welding process selected from the group consisting of welding, thermowelding, gas tungsten arc welding, tungsten inert gas welding, arc welding, laser welding, heat welding and thermoforming. Yet optionally, at least one of the step of sealing and reinforcing the plurality of sidewalls steps could further comprise the step of adding a melted drop, a plastic joint, silicone, any polysiloxane-based compounds, combination thereof, or any other material allowing to enhance the waterproofing properties and/or strength of the plurality of sidewalls and/or of the drainage base tray.

According to one possible embodiment, the method may further comprise the step of forming at least one shower curb. Optionally, the step of forming the at least one shower curb step can comprise a first step of folding one of a plurality of sidewalls of the foldable sheet at a first angle ranging from about 40 to about 45 degrees. Yet optionally, the step of the forming at least one shower curb step can comprise a second step of folding a folded sidewall at a second angle ranging from about 85 to about 95 degrees. The second step of folding could be repeated at least one other time, according to one's need. As illustrated in one possible embodiment of the accompanying drawings, the at least shower curb can be formed following a three-step folding method. For example, and without being limitative, a peripheral region of the foldable sheet can be successively folded at angles of 45, 87.95 and 92.05 degrees, respectively, to form a shower curb allowing a shower parts (e.g. a sliding glass door) to be mounted thereon and/or for a user to step on. It will readily understood that the mentioned dimensions and applications serve an illustrative purpose only and therefore should not be considered as limiting. Accordingly, the at least one shower curb could be used for different applications and could prevent an excess of liquid from overflowing from the drainage base tray.

According to one possible embodiment, the method may further comprise the step of sanding at least a portion of the upper surface of the foldable sheet. Optionally, the step of sanding can be carried out manually, automatically or with a corresponding device and/or machine (e.g. sandblasting). As it will be understood, the step of sanding could be substituted by any other step and/or method allowing altering the portion or an entirety of the upper surface of the foldable sheet.

According to one possible embodiment, the method may further comprise the step of sealing the foldable sheet about a draining region thereof. This step could be carried out concomitantly with a step of covering at least a portion of the foldable sheet with a corresponding coating. Alternatively, the step of covering at least a portion of the foldable sheet with a corresponding coating could include the step of providing the coating about a draining region of the foldable sheet. Optionally, the step of covering at least a portion of the foldable sheet with a corresponding coating could include at least one step selected from the group consisting of spraying an adhesive liquid, painting an adhesive layer, pasting an adhesive canvas, adding an adhesive layer, plating the single foldable sheet, chrome plating the single foldable sheet and galvanizing the single foldable sheet. Yet optionally, the step of covering at least a portion of the foldable sheet may further include the step of adding a flag for indicating an orientation of the foldable sheet. For example and without being limitative, the step of adding the flag could comprise step of providing an adhesive material, a notch, a drawing, combinations thereof, or any visual sign that facilitates the manufacturing and/or the installation process and/or method of the drainage base tray. As it will be understood, the steps of sealing and covering at least a portion of the foldable sheet with a corresponding coating, and more particularly in a draining region, allow enhancing the waterproofing properties of the drainage base tray and preventing the liquid from flowing under the drainage base tray through the drainage hole.

According to one possible embodiment, the method may further comprise the step of providing a finish to an upper surface of the foldable sheet. Alternatively, the step of providing a finish to an upper surface of the foldable sheet can include the step of altering a surface texture of the foldable sheet so as the surface has anti-slip properties. Optionally, the step of altering a surface texture of the foldable sheet could include a step selected from the group consisting of brushing, stamping, sandblasting, relief texturing, forming an anti-slip texture, combination thereof or any other methods/processes and/or devices/machines known by one skilled in the art.

According to one possible embodiment, the method may comprise the step of providing a computer-aided design (CAD) of the foldable sheet. For example, a CAD model may be generated at any steps of the method described in the present described, so as to accompany and guide the manufacture of the drainage base tray. The CAD model could be particularly useful to ensure a better reproducibility of the drainage base tray as the one described in the present description.

According to another aspect of the present invention, there is also provided a one-piece blank made of metallic foldable material and having portions for manufacturing a shower drainage base tray in accordance with a method such as the one defined in the present description. Alternatively, the one-piece blank could be made from any plastically-deformable materials, as they have previously been listed in the present description.

According to another aspect of the present invention, there is also a shower drainage base tray manufactured according to a method such as the one defined in the present description.

According to one possible embodiment, the shower drainage tray may comprise a main body made up of the one-piece blank, and may be provided with the at least one corresponding slope within the blank and with the draining hole.

According to one possible embodiment, the shower drainage base may tray comprise n folding lines, and n corresponding slopes defined within the main body of the one-piece blank, where n is an integer greater than 1. Alternatively, the shower drainage tray can comprise n folding lines, and n+1 corresponding slopes defined within the main body of the one-piece blank, where n is an integer greater than 1. Yet alternatively, the shower drainage tray can comprise n folding lines, and 2n corresponding slopes defined within the main body of the one-piece blank, where n is an integer greater than 1.

According to one possible embodiment, the shower drainage tray may comprise n corresponding sidewalls defined about the shower drainage tray, where n is an integer greater than 1.

According to one possible embodiment, the main body of the shower drainage base tray may be substantially rectangular. Alternatively, the main body of the shower drainage can be substantially square, circular, ovoidal, polygonal or having the shape, size and dimensions fitting a shower area according to one's need(s).

According to one possible embodiment, the shower drainage tray may be a linear shower drainage tray. Alternatively, the shower drainage tray could be any device, apparatus, tray, pans or the like and that are typically to permit liquids to flow from the shower.

According to one possible embodiment, the slope and corresponding sloping gradient can be defined between a pair of upper and distal side edges of the foldable sheet. It will be understood that the slope and corresponding sloping gradient are configured to allow the liquids contained in the shower drainage base tray to flow in direction of the draining hole.

According to another aspect of the present invention, there is also provided a shower drainage kit for use with a shower. Optionally, the drainage kit may comprise i) a shower drainage base tray such as the one defined in the present description; and ii) a grill component positioned, shaped and sized for placement over said shower drainage tray.

According to one possible embodiment, the grill component may have a substantially U-shaped cross-sectional profile. Optionally, the grill component can include a plurality of drainage holes for allowing wasted liquid to drain through said drainage holes and into the shower drainage tray.

Thus, as may also better be appreciated, the present invention is a substantial improvement over other conventional devices in that, by virtue of its design and components, as explained herein, and the particular configuration of the drainage base tray and/or components/accessories thereof according to the present system, one can manufacture it in a quicker, easier, simpler, more effective, more reliable, more versatile and more durable manner than what is possible with respect to other known conventional drainage base trays.

In summary, the present invention is advantageous over prior art shower drainage base tray. In one aspect, the method of manufacturing the drainage base tray for a shower as described in the present invention allows manufacturing a drainage base tray using a foldable sheet following a simple, yet efficient method and using a relatively low number of steps. Moreover, the number of welding step(s) is reduced, and the folding of the foldable sheet is simplified, hence decreasing the manufacturing/production time and associated costs. Accordingly, the drainage base tray manufactured following the steps described in the present description can be manufactured at a more competitive price.

In another aspect, the shower drainage base tray manufactured according to the method described in the present description and as it has also been described by the embodiments has improved sealing properties. Furthermore, dimensions of the shower drainage base tray and its related components contributes to its waterproofing properties, and are also compatible with market-standard dimensions of drains and pipes. Furthermore, when the shower drainage base tray is provided with a grill (e.g. a decorative grid), the drain remains easily accessible, although the presence of the grill. The grill can be replaceable at any time, without destroying the shower tray. The installation process of the shower drainage base tray is also simplified, which reduces the difficulties and challenges associated to the complexity of the installation of shower drainage base trays.

Of course, and as can be easily understood by a person skilled in the art, the scope of the claims should not be limited by the possible embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Furthermore, although preferred embodiments of the present invention have been briefly described herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to these embodiments and that various changes and modifications could be made without departing form the scope and spirit of the present invention, as defined in the appended claims and as apparent to a person skilled in the art.

Claims

1. A method of manufacturing a drainage base tray for a shower, the method comprising the steps of:

e) providing a foldable sheet of metallic material;

f) cutting a one-piece blank from the foldable sheet of metallic material;

g) folding the blank along at least one folding line in order to define at least one corresponding slope within the blank, the slope having an upper portion and a bottom portion defining a sloping gradient; and

h) providing the blank with a draining hole adjacent to the at least one folding line and in proximity of the bottom portion of the slope, for allowing waste liquid to drain via said draining hole of the drainage base tray.

2. A method according to claim 1, wherein step a) comprises either the step of providing at least one roll of foldable sheet of stainless steel, or the step of providing a plurality of foldable sheets of stainless steel.

3. A method according to claim 2, wherein step b) comprises the step of cutting a one-piece blank along a predetermined pattern; and wherein step b) further comprises the step of cutting a one-piece blank using a machining tool selected from the group consisting of a punching machine, a computer-numerical-control (CNC) machine and a jigsaw.

4. A method according to claim 3, wherein step c) comprises the step of folding the blank along at least one folding line using a corresponding press; and

wherein step c) further comprises either the step of folding the blank along n folding lines, so as to define n corresponding slopes within the blank, or the step of folding the blank along n folding lines, so as as to define n+1 corresponding slopes within the blank, or the step of folding the blank along n folding lines, so as as to define 2n corresponding slopes within the blank, and where n is an integer greater than 1.

5. A method according to claim 4, wherein step c) comprises the step of predetermining a height of the sloping gradient of the foldable sheet to establish an evacuation rate of waste liquid from the single foldable sheet towards the drainage hole; and wherein step c) further comprises the step of applying a force to the foldable sheet along at least a portion of the least one folding line to form the sloping gradient, the force being applied until a top portion of the foldable sheet reaches a corresponding depth of the drainage hole; and wherein the force is applied with a corresponding press having a substantially V-shaped head receivable into a complementary bottom portion.

6. A method according to claim 5, wherein step c) comprises the step of indicating a position of the at least one folding line onto the one-piece blank with a marking means selected from the group consisting of a pen, a laser, an engraving, an etching, a print, a carving, a laser, an illumining device and a projection.

7. A method according to claim 6, wherein step d) comprises the step of selecting a depth of the drainage hole; wherein step d) is carried out using a machining tool selected from the group consisting of a punching machine, a computer-numerical-control (CNC) machine and a jigsaw; wherein step d) further comprises the step of providing the draining hole with a corresponding recessed contour form; and wherein the step of providing the draining hole with a corresponding recessed contour form includes the step of cross-breaking the foldable sheet.

8. A method according to claim 7, wherein the step of providing the draining hole with a corresponding recessed contour form includes the step of punching the drainage hole with a punch tooling having a punch and a die; and wherein the punch has a substantially cylindrical profile engageable with a complementary bottom portion of the die.

9. A method according to claim 7, wherein the step of providing the draining hole with a corresponding recessed contour form includes the step of machining the draining hole; and wherein the step of machining the drainage hole is carried out using a machining tool selected from the group consisting of a drill bit, a punching machine, a computer-numerical-control (CNC) machine and a jigsaw.

10. A method according to claim 7, wherein at least one of steps b), c) and d) of the method is carried out using a corresponding press, or alternatively, a plurality of steps b), c) and d) of the method are carried out using a same corresponding press, or alternatively, all of steps b), c) and d) of the method are carried out using a same corresponding press.

11. A method according to claim 1, wherein the method further comprising the step of:

i) folding a peripheral portion of the blank for providing the shower drainage base tray with at least one corresponding sidewall being positioned, shaped and sized for containing waster liquid within the shower drainage tray.

12. A method according to claim 11, wherein the at one corresponding sidewall is defined by at least one fold of a corresponding portion of the one-piece blank, or alternatively, by a plurality of folds of corresponding portions of the one-piece blank.

13. A method according to claim 12, wherein step e) comprises the step of folding n peripheral portions of the blank, so as as to define n corresponding sidewalls about the shower drainage base tray, where n is an integer greater than 1.

14. A method according to claim 13, wherein step e) comprises the step of folding a peripheral portion of the blank so as to define at least one corresponding open-ended sidewall having a substantially U-shaped cross-sectional profile.

15. A method according to claim 13, wherein step e) comprises the step of folding a peripheral portion of the blank so as to define at least one corresponding closed-ended sidewall having a substantially rectangular cross-sectional profile.

16. A method according to claim 12, wherein step e) comprises the step of bending at about 90 degrees at least one corresponding peripheral edge of the foldable sheet; and wherein step e) further comprises the step of guiding the foldable sheet during bending of the at least one sidewall; wherein the step of guiding the foldable sheet comprises engaging a guiding mechanism to maintain the foldable sheet in position during bending of the at least one sidewall.

17. A method according to claim 16, wherein step e) further comprises the step of sealing a plurality of sidewalls of the drainage base tray; wherein step e) further comprises the step of reinforcing a plurality of sidewalls of the drainage base tray; wherein the step of reinforcing a plurality of sidewalls comprises the step of welding a plurality of sidewalls with one another; and wherein the step of reinforcing a plurality of sidewalls is carried out using a welding process selected from the group consisting of welding, thermowelding, gas tungsten arc welding, tungsten inert gas welding, arc welding, laser welding, heat welding and thermoforming.

18. A method according to claim 17, wherein the method further comprises the step of forming at least one shower curb; wherein the step of forming at least one shower curb comprises a first step of folding one of a plurality of side portions of the foldable sheet at a first angle ranging from about 40 to about 45 degrees; wherein the step of forming at least one shower curb step comprises a second step of folding a folded side portion at a second angle ranging from about 85 to about 95 degrees; and wherein the second step of folding is optionally repeated at least one other time.

19. A method according to claim 18, wherein the method further comprises a least one additional step selected from the group consisting of: i) sanding at least a portion of an upper surface of the foldable sheet; ii) sealing the foldable sheet about a draining region thereof; iii) covering at least a portion of the foldable sheet with a corresponding coating; iv) providing a coating about a draining region of the foldable sheet; and v) providing a finish to an upper surface of the foldable sheet.

20. A method according to claim 19, wherein the step of covering at least a portion of the foldable sheet with a corresponding coating includes at least one step selected from the group consisting of spraying an adhesive liquid, painting an adhesive layer, pasting an adhesive canvas, adding an adhesive layer, plating the single foldable sheet, chrome plating the single foldable sheet and galvanizing the single foldable sheet; and wherein the step of altering a surface texture of the foldable sheet includes a step selected from the group consisting of brushing, stamping, sandblasting, relief texturing and forming an anti-slip texture.