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.

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.