Patent Publication Number: US-10314441-B2

Title: Shower hob apparatus

Description:
FIELD OF THE INVENTION 
     The invention relates to shower construction. In particular, the invention relates, but is not limited, to an apparatus used in the construction of a shower hob. 
     BACKGROUND TO THE INVENTION 
     Reference to background art herein is not to be construed as an admission that such art constitutes common general knowledge in Australia or elsewhere. 
     Showers hobs are traditionally constructed around the perimeter of a shower cubicle to confine water and prevent leakage. Hobs are commonly constructed of aerated concrete blocks or bricks which are affixed to the floor. Waterproofing and bedding compounds are applied to the inside of the hob and bathroom tiles are affixed on top. Shower trays can also be fitted over the hob. A shower screen is commonly sealed directly to the tiles or the shower tray. 
     One problem with traditional shower hob constructions is that, as tile grout is porous, water can seep between the tiles. This can result in the tiles detaching from the hob, disintegration of the waterproof layer, and damage to the surrounding floor or walls. 
     Another problem is that the concrete blocks or bricks are generally quite wide and this results in a large step into the shower cubicle. Apart from being unappealing to the eye, this can be a safety hazard. 
     Another disadvantage of traditional shower hob construction is that the process of constructing the shower hob can take days to complete. The concrete blocks or bricks must be adhered to the floor before the waterproofing membrane can be applied, and the waterproofing must be dry before the bedding can be laid. The tiles cannot be grouted until the tile adhesive has set and the shower screen cannot be installed until the tiles are laid. 
     Modern shower hobs may be constructed using aluminium angle rather than concrete blocks or bricks. Once the angle is affixed to the floor, the waterproofing and bedding compounds are applied over the angle and the inside of the shower hob. The tiles must then be laid, set and grouted, prior to the installation of the shower screen. Whilst this type of construction may reduce water leakage and decrease the size of the step into the shower cubicle, the shower hob must still be constructed in a step-wise process and the shower screen cannot be installed until the waterproofing, bedding and tiling steps are completed. 
     OBJECT OF THE INVENTION 
     It is an aim of this invention to provide a shower hob apparatus which overcomes or ameliorates one or more of the disadvantages or problems described above, or which at least provides a useful alternative. 
     Other preferred objects of the present invention will become apparent from the following description. 
     SUMMARY OF THE INVENTION 
     Throughout the specification, the term “screen” shall be taken to include glass screens and panels, and screens and panels made from other materials such as Perspex, plastics, metal, or the like. 
     In one form, although it need not be the only or indeed the broadest form, there is provided a shower hob apparatus for forming a shower hob including: 
     a screen retaining portion adapted to receive a screen, the screen retaining portion having at least one side wall; and 
     a base adapted to engage with a floor surface; 
     wherein the base extends laterally to the side wall of the screen retaining portion. 
     Preferably, the screen retaining portion is in the form of a channel. More preferably, the channel includes a floor and two side walls extending substantially perpendicular to the floor of the channel to form a substantially U-shaped channel. Preferably, the side wall or walls abut a screen. The screen retaining portion may have a drainage hole. Preferably the drainage hole is located in the floor of the channel. 
     Preferably, the base is substantially planar having an upper and lower surface. In a preferred form, the lower surface of the base is fixed to the floor surface by the use of an adhesive or the like. 
     Alternatively, the base may be fixed to the floor surface by the use of one or more fasteners. Preferably, the base includes a groove on the upper surface which indicates a preferred position for making at least one aperture and inserting at least one fastener, such as a screw, to fix the base to the floor surface. Suitably, the groove may be a weakened portion of the shower hob apparatus such that it is relatively easy for a user to form an aperture in the groove with the appropriate tool, such as a self-tapping screw or a drill. The groove is preferably sized and shaped to allow the screw to be at least partially countersunk in the base. 
     Preferably, a free end of the base is tapered to assist in the application of a waterproof layer. More preferably, the free end of the base is tapered at an angle of 45 degrees or less, relative to a longitudinal axis of the base. 
     In a preferred form, the shower hob apparatus includes a tile height indicator. 
     The tile height indicator preferably includes a tile support member extending laterally to a side wall of the screen retaining portion. The tile height indicator is preferably adapted to receive a tile. 
     Alternatively, the tile height indicator may be in the form of a mark or notch on the shower hob apparatus for indicating a preferred tile position. 
     Preferably, the tile height indicator is lower than the screen retaining portion. More preferably, the tile height indicator is lower than the floor of the screen retaining portion. 
     In a preferred form, the shower hob apparatus includes at least one longitudinal member which forms a connection between the base and the screen retaining portion. In a preferred form a single longitudinal member forms a connection between the base and the screen retaining portion. Preferably the longitudinal member, the base, and the screen retaining portion collectively define a cavity. In another preferred form the shower hob apparatus may include two longitudinal members, located between the base and the screen retaining portion. The two longitudinal members preferably define a hollow interior. 
     The base preferably extends laterally from an end of a longitudinal member. The screen retaining portion is preferably located at an opposite end of the longitudinal member, distal to the base. 
     The longitudinal member(s), base and screen retaining portion are preferably integrally formed as an extrusion. 
     Preferably, the tile height indicator extends laterally from a longitudinal member or a side wall of the screen retaining portion of the shower hob apparatus. 
     According to another form of the invention, there is provided a shower hob comprising the shower hob apparatus as hereinbefore described with a waterproof layer, a bedding layer, and a tiled surface arranged on top of the base. Preferably the shower hob further comprises a screen affixed in the screen retaining portion. 
     According to another form of the invention there is provided a method of constructing at least a portion of a shower cubicle using a shower hob apparatus as herein described, the method including the steps of: 
     fixing at least one shower hob apparatus to a floor surface; 
     inserting a screen into the screen retaining portion of the shower hob apparatus; 
     applying a waterproof layer over the floor surface and at least a portion of the base of the shower hob apparatus; and 
     constructing a tiled floor over the waterproof layer. 
     According to yet another form of the invention there is provided a method of constructing at least a portion of a shower cubicle, the method including the steps of: 
     fixing a base of at least one shower hob apparatus to a floor surface; 
     inserting a screen into a screen retaining portion of the shower hob apparatus; 
     applying a waterproof layer over the floor surface and at least a portion of the base of the shower hob apparatus; and 
     constructing a tiled floor over the waterproof layer. 
     Preferably, the step of constructing the tiled floor includes applying a bedding layer over the waterproof layer, and applying tiles over the bedding layer. 
     Preferably, the bedding layer is applied to a level indicated by a tile height indicator on the shower hob apparatus. The tile height indicator may be a mark or notch on the shower hob apparatus. 
     The tile height indicator may also be a tile support member. Preferably, one or more tiles overlie the tile support member which extends from a longitudinal member of the shower hob apparatus. The tiles are preferably laid on an incline towards a drain in the shower cubicle. 
     Preferably, the step of fixing the shower hob apparatus to the floor surface includes applying an adhesive to the base of the shower hob apparatus. Alternatively, the base of the shower hob apparatus may be fixed to the floor by at least one fastener such as a screw. One or more apertures may be made in the groove of the base of the shower hob apparatus to receive the screw or screws. 
     The shower hob apparatus and screen preferably form at least one side of the shower cubicle. 
     According to yet another form of the invention there is provided a shower cubicle including: 
     a shower hob apparatus fixed to a floor surface, the shower hob apparatus including a screen retaining portion having at least one side wall, and a base extending laterally to the side wall of the screen retaining portion; 
     a screen inserted into the screen retaining portion of the shower hob apparatus; 
     a waterproof layer located over the floor surface and at least a portion of the base of the shower hob apparatus; 
     a bedding layer located over the waterproof layer; 
     a tiled surface located over the bedding layer, wherein the tiled surface slopes down from the shower hob apparatus towards a drain; 
     wherein, the shower hob apparatus defines one or more sides of the shower cubicle. 
     Further features and advantages of the present invention will become apparent from the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       By way of example only, preferred embodiments of the invention will be described more fully hereinafter with reference to the accompanying figures, wherein: 
         FIG. 1  is an end view of a shower hob apparatus according to an embodiment of the invention; 
         FIG. 2  is a top perspective view of the shower hob apparatus illustrated in  FIG. 1 ; 
         FIG. 3  is a cross section of a shower hob according to an embodiment of the invention; 
         FIG. 4  is a plan view of two sections of shower hob apparatus joined to form two sides of a shower cubicle; 
         FIG. 5  is a plan view of three sections of shower hob apparatus joined to form three sides of a shower cubicle; and 
         FIG. 6  is a cross section of a shower hob according to another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1 to 3  illustrate a shower hob apparatus  10  having a screen retaining portion  100  for receiving a screen  200  (see  FIG. 3 ). The screen retaining portion  100  includes a floor  110  and two side walls  120 ,  130  extending vertically to form a substantially U-shaped channel  140 . 
     The shower hob apparatus  10  also includes a base  300  which extends laterally to the side wall  130  of the screen retaining portion  100 . The base  300  has a planar portion  310  which can be fixed to a floor surface (not shown), such as concrete or wooden floor boards, by an adhesive. The base  300  may also be fixed to a floor surface by at least one fastener such as a screw. The groove  320  on the upper surface of the base  300  provides an indicator for the optimal position of one or more apertures for receiving one or more screws. 
     The base may also include grooves or notches on the lower surface of the planar portion  310  for adhering the base  300  to the floor surface. One end of the base  330  is tapered to a point which assists in the application of the waterproof layer  600 , as described below. 
     In a preferred embodiment, the shower hob apparatus  10  also includes two longitudinal members  400 ,  410  which connect the base  300  and the screen retaining portion  100 . As shown in  FIGS. 1 to 3 , the base  300  is located at one end  420  of the longitudinal member  400  and the screen retaining portion  100  is located at another end  430  of the longitudinal member  400 , distal to the base  300 . 
     The two longitudinal members  400 ,  410  preferably define a hollow interior  440 . The base  300  preferably extends laterally from a longitudinal member  410 , such that the base  300  and the longitudinal members  400 ,  410  together form a substantially L-shaped member. 
     As shown in  FIG. 2 , the longitudinal members  400 ,  410 , base  300  and channel  140  of the screen retaining portion  100  are integrally formed as an extrusion. The extrusion can be any suitable length. Advantageously, the height and width of the shower hob apparatus  10  can also be varied to suit different applications. 
       FIGS. 1 to 3  illustrate a shower hob apparatus  10  having a tile height indicator in the form of a tile support member  500 . The tile support member  500  preferably extends laterally from longitudinal member  410  of the shower hob apparatus  10 . As shown in  FIGS. 1 to 3 , the tile support member  500  is positioned lower than the channel  140  of the screen retaining portion  100 . 
     In an alternative embodiment, the tile height indicator may be a mark or notch (not shown) on longitudinal member  410  for indicating the preferred level of the bedding layer  700  and position of the tiles, as described below. 
       FIG. 3  shows a portion of a shower hob constructed according to an embodiment of the invention. The shower hob includes a shower hob apparatus  10 , a waterproof layer  600 , a bedding layer  700 , and tiles  800 . A screen  200  has been installed into the screen retaining portion  100  of the shower hob apparatus  10  such that the screen  200  is in an upright position. 
     In an alternative form, as illustrated in  FIG. 6 , the shower hob apparatus  10  includes a single longitudinal member  400 . Compared to the shower hob apparatus  10  illustrated in  FIGS. 1 to 3 , the second longitudinal member  410  has been removed. In such an embodiment the hollow interior  440  (illustrated in  FIG. 1 ) effectively becomes a cavity  440  (illustrated in  FIG. 6 ). The cavity  440  may receive the waterproof layer  600  and bedding layer  700  illustrated in  FIG. 3 . It is preferred that the waterproof layer  600  extends at least partially up the inner side of the longitudinal member  400 . 
     Also illustrated in  FIG. 6  is an optional drainage hole  111  located in floor  110  of the screen retaining portion  100 . The drainage hole  111  fluidly connects the screen retaining portion  100  to the cavity  440  to communicate any liquid that may reach the screen retaining portion  100  into the cavity  440 . It will be appreciated that although the drainage hole  111  is only illustrated in relation to the embodiment of the show hob apparatus illustrated in  FIG. 6 , that it could be provided in relation to other embodiments, including the embodiment illustrated in  FIGS. 1 to 3 . 
     In use, the base  300  of the shower hob apparatus  10  is fixed to a concrete slab or other floor surface, preferably using an adhesive. The base  300  may also be fixed to the floor surface by at least one fastener such as a screw. The groove  320  on the upper surface of the base  300  provides an indicator for the preferred location of the aperture or apertures for receiving one or more screws to fix the base  300  to the floor surface. As shown in  FIGS. 1, 3, and 6 , the groove  320  is a substantially v-shaped recess in the base  300  of the shower hob apparatus  10 . Due to the size and shape of the groove  320 , the screw (not shown), once inserted into the aperture (not shown) in the groove  320 , will be at least partially countersunk in the base  300 . 
     It is preferred that the shower hob apparatus  10  is level once fixed to the floor surface, and packers can be used if necessary to level the shower hob apparatus  10 . Wall channels (not shown) can also be fitted to the floor surface adjacent the wall or walls of the shower cubicle. An infill channel (not shown) can also be fitted to the floor surface to form a doorsill. 
     When fixed to a floor surface, the shower hob apparatus  10  is rigid and provides support for a screen  200  which is inserted into the channel  140  of the screen retaining portion  100  to form at least a portion of a shower cubicle. To ensure the screen  200  is firmly secured in the channel  140 , packers  210  can be inserted underneath and behind the screen  200 . Preferably, the screen  200  abuts the side wall  130  of the shower hob apparatus  10 . Any gaps between the screen  200 , the shower hob apparatus  10 , and the wall channel (not shown) can be filled with silicone  220 ,  230 ,  240  or other suitable sealant. Silicone, or another suitable sealant, can also be used to fill gaps between the wall channel (not shown) and the shower hob apparatus  10 . 
     A waterproof layer  600  is then applied over the floor surface and a portion of the shower hob apparatus  10 , preferably the base  300 . The waterproof layer  600  can be formed from a liquid waterproofing material, a fibreglass membrane, or any other suitable waterproofing agent. As shown in  FIG. 3 , it is preferred that the waterproof layer  600  is applied up to the tile support member  500 . However, it will be appreciated that it is not essential for the waterproof layer  600  to be applied to this level. For example, the waterproof layer  600  could even be applied over the tile support member  500  up to the channel  140  of the screen retaining portion  100 . One end  330  of the base  300  tapers off towards the floor surface which assists in the application of the waterproof layer  600 . As shown in  FIGS. 1, 3, and 6 , the tapered end  330  of the base  300  is tapered at an angle of 45 degrees or less, relative to a longitudinal axis of the base  300 . 
     Once the waterproof layer  600  has been applied, a bedding layer  700  is applied over the waterproof layer  600  and up to the level indicated by the tile support member  500 . The bedding layer may be comprised of mortar, cement and sand mix, or any other suitable material. Tiles  800  are then applied to the surface  710  of the bedding layer  700 , using the tile support member  500  as a guide for positioning the tiles  800  which abut the shower hob apparatus  10 . The tile support member  500  is preferably located below the screen retaining portion  100 , such that the tiles  800  once laid, are roughly aligned with the floor  110  of the channel  140  of the screen retaining portion  100 . 
     It will be appreciated that the bedding layer  700  and tiles  800  will typically be laid around a drain (not shown) in the floor of the shower cubicle. Persons skilled in the art will also appreciate that the tiles  800  are typically laid on an incline towards the drain to allow for proper drainage of water. 
     The shower hob apparatus  10  and screen  200  preferably form at least one side of the shower cubicle. As shown in  FIGS. 4 and 5 , sections of shower hob apparatus  12 ,  14 ,  16  can be joined, for example by bending and welding, to form two or more sides of the shower hob.  FIG. 4  illustrates a two sided shower hob, constructed by joining two sections of shower hob apparatus.  FIG. 5  illustrates a three sided shower hob, constructed by joining three sections of shower hob apparatus. 
     Importantly, as the screen  200  is installed directly onto the shower hob apparatus  10 , rather than mounted over or on the tiles  800 , the screen  200  can be installed at any time during the construction process. There is no need to wait until the shower hob  10  has been waterproofed, bedded and tiled before installing the screen. For example, the screen  200  can be installed as soon as the shower hob apparatus  10  is fixed in position, after the waterproof layer  600  is applied, or even after the entire tiling process. The result is a more streamlined construction process and reduced labour costs. 
     The shower hob apparatus  10  of the present invention is much more compact than bricks or aerated concrete blocks and thus the resultant step into the shower cubicle can be much smaller than conventional shower hobs. Further, use of the shower hob apparatus  10  reduces the risk of water leakage as water cannot penetrate the shower hob apparatus  10 . 
     The tile support member  500  provides an easy reference point for positioning the tiles  800  and the indicating the optimal depth of the bedding layer  700 . Another advantage of the present invention is that the tiles  800  can be applied directly to the outer side of the shower hob apparatus  10  which reduces bedding costs. 
     Advantageously, the shower hob apparatus  10  of the present invention can be made from one piece which provides a strong foundation for constructing the shower hob and supporting the screen  200 . Rather than affixing the screen  200  to the tiles or the shower tray, the screen  200  is installed directly into the shower hob apparatus  10  itself. This results in greater stability than prior art shower hob construction. Prior art apparatuses generally require more parts which may result in decreased stability of the shower hob, and thus the constructed shower cubicle, with increased labour and material costs. 
     Yet another advantage of the present invention is that the tapered end  330  of the base  300  provides a smooth transition from the floor surface to the shower hob apparatus  10 . This provides a relatively smooth surface which can assist in the application of the waterproof layer  600 . The tapered end  330  reduces the risk of a waterproof membrane catching and tearing on a sharp, raised end of a shower hob apparatus. The tapered end also reduces the risk of a user inconsistently applying a liquid waterproofing material to the shower hob apparatus, as the waterproofing material can be applied in a single smooth motion, rather than up and over a sharp, raised end. 
     The size and shape of the groove  320  of the base  300  offers another advantage. As the groove  320  is recessed into the base  300 , the screw, once inserted into the aperture in the groove  320 , will be partially countersunk in the base  300 . The countersinking of the screw reduces the risk of the waterproof layer  600 , in the form of a waterproof membrane, catching and tearing on a raised screw. It may also reduce the risk of a user inconsistently applying a liquid waterproofing material to the shower hob apparatus as the waterproofing material can be applied in a single smooth motion, rather than up and over a raised screw. 
     In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not to be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step etc. 
     The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention. 
     In this specification, the terms ‘comprises’, ‘comprising’, ‘includes’, ‘including’, or similar terms are intended to mean a non-exclusive inclusion, such that a method, system or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.