The invention to which this application relates is a panel of a type which can be used particularly, although not necessarily exclusively, in a bathroom environment for use in a shower assembly as part of a former tray on which a person stands to support the same when showering and, in another form, to mask part of the side of a bath.

The provision of showers and/ or baths to allow a person in a premises to bathe, is an essential feature of most premises. Increasingly, as well as the functionality of the shower and bath, there is a demand for the appearance of the same to be visually attractive and also to be able to prevent leakage of water from the shower or bath into the surrounding room or below the room.

In order to provide these functions, it is known to provide panels, typically formed of reinforced plastics materials, which, when used for a shower, can be placed onto a floor or joists and which then form a surface onto which a covering material such as tiles, sheet material or the like may be placed to form an external surface or alternatively the panel surface may form the external surface directly. In any case the water from the shower impacts onto the said external surface and on which the person is standing when they use the shower. The water then collects on the external surface and flows to a drainage aperture provided in the panel which, in turn, is attached to a drainage system to allow the water to be collected and carried away for disposal. In another embodiment, it is known for baths to be provided with one or more panels which are fitted so as to form sidewalls of the bath and which act to protect the walls of the bath itself from impact which may cause leakage and, secondly, serve to provide a more decorative and/or attractive appearance to the bath perhaps due to the external surface shaping of the panel and/ or a decoration layer applied thereto to form the external surface of the panel. The use of the panel also provides a more uniform sidewall structure to the bath and, with the use of sealant, or sealing strips at the edge of the panel where the same abuts the bath, side wall of the room and/ or floor of the room, the panels help to prevent the ingress of water to the space between the underside of the bath and the floor and walls of the room which, if not prevented, can collect and cause damage to the floor structure on which the bath is located. In these embodiments, there is a need for the panel which is provided to have sufficient strength so as to withstand the weight of a person standing on the same when having a shower and/ or to withstand impact when the same is used as a bath panel. If the panel is not sufficiently strong and/ or is too brittle, then the same will crack and, once this occurs, it is commonly the case that the crack will gradually increase in size due to the flexing of the same during subsequent use until, eventually the panel fails or disperses into a number of parts.

A further problem with regard to panels of this type, is that the dimensions of the location at which the panel is to be installed varies from building to building. Thus, even if measurements are taken prior to installation, it is often found that when the panel is delivered on site, the measurements which may already have been taken are inaccurate or there are specific requirements which need to be taken into account at the time of installation. As a result it is conventionally the case that the installer will be required to alter the dimensions of the panel by cutting the same in a relatively uncontrolled manner and, more importantiy, in a manner which serves to weaken the strength of the panel and alters the integrity of the same and so can cause the same to be more susceptible to failure.

This also leads to significantly longer installation times which can lead to additional expense and, if the installer is under pressure to complete a set number of installations per day can lead to inferior installation work being performed.

The aim of the present invention is therefore to provide a panel which can be used in a form which has a required strength for the proposed use and, furthermore, to provide a panel in a form in which dimensions of the same can be adjusted in a controlled manner and without significantly affecting the strength and integrity of the panel.

In a first aspect of the invention, there is provided a panel for use in a bathroom apparatus in the form of a bath or shower, said panel having a first surface and a second, opposing, surface, and wherein at least one of the length and width of the panel are selectively adjustable to one of a range of predetermined dimensions defined by at least one guide formation on the panel which allows a portion of the panel to be removed by breaking or cutting the panel along a selected guide formation in order to select one of the predetermined dimensions.

In one embodiment the said guide formation is a line of weakening such that the selection of at least one predetermined dimension can be performed by breaking the portion from the panel along the guide formation on site at the location of installation of the panel.

In one embodiment, the provision of a set of guide formations can be achieved by providing a number of spaced apart lines of weakening in the panel.

In one embodiment the said at least one guide formation depends across the panel from opposing edges of the panel.

In one embodiment the said at least two edges of the panel are parallel.

Typically, in a set of guide formations there are a plurality of parallel guide formations spaced apart inwardly from, and in parallel with, an edge of the panel so that one of the guide formations in the set can be selected for the guidance of a line of cutting or breaking, such as by running a knife along the guide formation so as to reduce the length and/ or width dimension of the panel at the appropriate location.

In one embodiment, guide formations are provided at opposing edges of the panel.

In one embodiment, the number of guide formations at each of said edges of the panel, is varied such that, at one edge, there is provided a greater number of parallel guide formations than at any other edge.

In one embodiment first and second opposing edges have a plurality of guide formations provided inwardly therefrom, and in one embodiment, the same number, and a further edge of the panel has a smaller number of guide formations spaced inwardly therefrom. In one embodiment, the edge of the panel which has the lowest or no guide formations adjacent thereon is that which lies closest to a drain aperture provided in the panel and/ or the edge which has the greatest number of guide formations spaced inwardly therefrom is the edge which is furthest removed from a drain aperture in the panel.

In another embodiment, said guide formations are provided so as to be spaced inwardly from opposing edges of the panel and in one embodiment, the same number of guide formations are provided at each end of the panel.

Typically the depth of the guide formation is less than the depth of the panel adjacent thereto.

In one embodiment, the second surface of the panel includes a plurality of ribs so as to maintain the strength of the panel during use.

In one embodiment, the ribs are provided in the form of a series of interconnected hexagons provided in a honeycomb patterned relationship across at least part of the area said second surface of the base. Typically said area extends across and between the edges of the panel or, at those edges where provided, the innermost guide formations on the panel.

In one embodiment, a second portion of ribs of a second form to the first portion is provided, and in one embodiment, are provided to be substantially parallel with the guide formations and/ or adjacent panel edge.

In one embodiment, the said panels include fixing locations which may be wholly, but are more typically, partially formed and, when partially formed, the same typically extend inwardly from the second surface towards but not to the first surface of the panel and can be accessed by passing location means through the remaining wall of the fixing locations, if required.

Typically, the fixing locations which are masked from the external face, are selectively used depending on the particular guide formation which has been used to select the dimension of the panel. Typically sufficient groups of fixing locations are provided and located in order to allow a group to be available to be used and the said group which is selected is dependent upon the particular dimension to which panel has been adjusted at the location of installation. This means that said location means can be used at positions adjacent to the external edge of the panel so that they can be then used to locate the panel in position.

In one embodiment, the panel is used as a tray for a shower on which a person stands or a former tray for a shower which receives a material thereon which forms the surface on which the person stands.

Typically, when the panel is used as a shower tray, the shower tray can be raised above a support surface by a plurality of feet which are engaged with the internal side of the panel.

In one embodiment, the feet are provided with a portion which is located on the support surface and, at the opposing end, a portion which is located with the second surface of the panel.

In one embodiment, the portion which is provided for location with the panel, is formed so as to allow engagement with the ribs to thereby allow the feet to be located with and support the panel adjacent to the edges of the panel once the dimensions of the same have been selected.

In one embodiment, the panel is used to form a sidewall panel for a bath.

In one embodiment, said panel when provided for use with the bath includes location means at the opposing end from which guide formations are provided so as to allow the said panel to be attached to another panel arranged substantially perpendicular therewith so as to allow the location of two bath panels in offset locations so as to substantially mask two sides of the bath. In another embodiment the location means or further location means, are provided to allow the panel to be attached to a support surface.

In one embodiment, at least one of the edges of the bath is adjacent a wall against which the bath is located. Typically, the panel is formed from a Sheet Moulding Compound (SMC) material, but it should be appreciated that this need not always be the case.

In one embodiment, there is provided a panel which can be used for different purposes but, in each case, is provided with at least one guide formation and ribs formed therein so as to allow the panel to be cut to a required size within a predetermined range of sizes whilst, at the same time, ensuring that the cut which is made, does not adversely impact on the integrity or strength of the panel which is formed.

In one embodiment the panel includes a covering material applied to the first surface of the same in order to provide a protective and/ or decorative effect.

In a further aspect of the invention there is provided a method for the installation of a panel as part of bathroom apparatus in the form of a shower or bath, said method comprising the steps of producing a panel with maximum required length and width dimensions, identifying the particular width and length dimension of the area into which the panel is to be installed, removing a portion or portions of the panel, if required, to reduce the length and/ or width dimensions of the panel to allow the same to be fitted in position and wherein the adjustment of the length and/or width of the panel is achieved by selecting to break the panel along a selected one or more guide formations formed on the panel at the time of manufacture.

In one embodiment, the panel is manufactured to include a relatively smooth and/ or shaped first surface and a second surface which is provided with a series of strengthening ribs.

Specific embodiments of the invention are now described with reference to accompanying drawings wherein:

Figures la-c, illustrate a panel in the form of a shower tray in accordance with one embodiment of the invention. Figureld illustrates the panel of Figures la-c adjusted to different dimensions in accordance with the invention.

Figures 2a-b, illustrates the panel of Figures la-c, with support feet in accordance with one embodiment of the invention;

Figures 3a -c illustrate the attachment of the feet of Figures 2-b to the panel in greater detail;

Figures 4a-k illustrate support feet of Figures 2a-3b in accordance with one embodiment; and

Figures 5a-r illustrate a further embodiment of a panel in accordance with the invention for use as a masking panel for the side of a bath.

Referring firstly to Figures la-d, there is illustrated a panel 2 which, in this embodiment is provided to be used as a shower tray in accordance with one embodiment of the invention in which the panel is provided to be the tray or former tray on which a person taking a shower stands and in which the water from the shower collects and passes to a drainage aperture 17. The panel 2 has a first surface which forms the external face 4, or has a covering material such as tiles or sheet material thereon which forms the external face 4, and on which the user stands when using the shower. Once installed in a bathroom the panel is positioned on, or adjacent to, a support surface such as a floor or joists, and a second surface 6 of the panel is located so as to be the internal surface. The second surface of the panel, in this embodiment, includes a portion of a plurality of strengthening ribs 8 which are formed in a hexagonal honeycomb pattern and a portion of a plurality of ribs 10 of a different form to the ribs 8 and the ribs 10 are provided so as to lie substantially parallel with each other and parallel with the particular edge 12, 14, 14’, 16 of the panel 2 from which the same are inwardly offset.

In this embodiment, at the first edge 12 of the panel there are provided a greater number of parallel ribs 10 than at the opposing edge 16 which lies adjacent to a drain aperture 17 which allows water to drain from the external surface 4 to a drain system connected to the underside of the drain aperture. At the edges 14, 14’, there are provided the same number of ribs, 10.

There is also provided a guide formation in the form of a line of weakening 18 and the guide formations are located intermediate adjacent ribs 10 or a rib and the edge as shown in Figure lb which form a guideline formation. It should be appreciated that rather than a line of weakening in which the depth of the guide formation is typically less than the depth of panel adjacent thereto, the guide formation could be formed by other or a combination of means such as a mark, or visual guide such as a change in colour or the like. The guide formations 18 therefore define a range of possible smaller dimensions to which the panel can be convenientiy changed to and thereby allows the installer, typically at the time and location of installation of the panel, to adjust the size of panel to suit the dimension of the area into which the panel is to be installed at that particular location. In this embodiment the guide formations 18 are equally spaced apart. In one embodiment the guide formations depend inwardly from the second surface 6 so that the same have shallower depth than the adjacent parts of the panel and furthermore are not visible from the first surface 4 of the panel.

The installer will therefore initially have the panel with the maximum dimensions and then if necessary select to reduce the length and or width dimensions of the panel by selecting a guide formation which is best suited to the required dimension and then break or cut the panel along the selected guide formation to remove a portion of the panel. As each guide formation is typically located adjacent to one side of a rib 10 and typically the face of the rib facing towards the edge of the panel, then once a particular guide formation 18 has been selected and the panel cut, then the rib 10 which is closest to the selected guide formation 18 forms the edge of the panel and also ensuring that the strength of the panel is maintained. A panel which has been cut along guide formations 18’ and 18” of Figure lb, is show in Figure Id.

Thus, as the installation of these panels tends to be performed in houses or other premises which have differing dimensions, so the problems which are conventionally experienced are overcome by the provision of the panel which can be selectively formed to dimensions within a predetermined range of dimensions on site and ensuring that a neat cut is achieved and ensuring that the panel has an external edge is provided by a rib 10 and the strength of the same is retained by the remaining ribs 10 and ribs 8.

It will therefore be appreciated that the panel dimensions can easily be adapted in accordance with the invention and the particular range of dimension adjustments which can be made is determined by the number of guide formations and their locations with respective edges of the panel. It should be appreciated that this may change from panel to panel and with respect to the particular use of the same.

Figures 2a and 2b illustrate the panel 2 provided with support feet 20, with Figure 2a showing the panel in position to be placed in the direction of arrow 22 onto a support surface and Figure 2b showing the panel having been turned upside down. The feet 20 have, at one end, 24, a portion 26 to allow the same to locate on the support surface such as a floor or joists and which includes a threaded shaft 29 to allow adjustment of the height of the feet by selective rotation of the portion 26 and threaded shaft 29 with respect to the portion 28 which has a female threaded portion 31 includes at the opposing end, location means 30 which allow the engagement of the foot with the hexagonal ribs 8 of the panel using engagement formations 32 and/or with one or more of the ribs 10 via slots 34, and therefore allow the feet to be located as required in a spaced configuration across the second surface of the panel to provide the required support of the panel at a spaced distance from the support surface. The feet are shown in more detail in Figures 3a-c in which the panel is shown turned through 180 degrees and 4a-k. In Figures 3c and 4h the components of the feet are shown in cross section along line AA.

Figures 5a-r illustrate another form of panel 36 in accordance with the invention. In the embodiment shown in Figure 5a the panel is provided for use as a sidewall of a bath assembly 52. In this assembly there is provided a first panel 36 which forms a first sidewall and a second panel 36' which forms a second side wall, perpendicular to the first. In Figures 5b-l there is illustrated the panel 36 in more detail and in Figures 5m-r three panels 36 are shown in position to form a U shaped side wall to form a space 72 into which the bath can be positioned The sidewalls provide a decorative effect and/ or protect the walls 54 of the bath structure from damage and can also be used to seal against the ingress of water between the underside 56 of the bath and the support floor 58 and building walls 60 by the use of sealing means at locations 62.

The panel 36 again has a first surface 38 which can form the external face of the sidewalls or which may receive an outer covering which forms a decorative external face, and a second, internal, surface 40 which includes a first portion of support ribs 42 and, at edges 44, 46, a second portion of strengthening ribs 48. Also provided inwardly from, and parallel with the edges 44, 46 are first and second sets 64, 66 of guide formations 50 and which are each located adjacent to a rib 48. Once again, the panel can be reduced in size, and in this embodiment, reduced in length, by selectively breaking or cutting the panel along selected guide formations and in this embodiment this could be either by removing a portion of the panel at one edge 44 or 46 or, alternatively by removing the same size of portion of the panel from both edges 44,46 of the panel by selecting the appropriate guide formation 50 from each set 64, 66 and, once removed, the rib 48 which lay adjacent to the selected guide formation forms the edge of the bath panel. This is illustrated in Figure 5i which illustrates the panel 36 of Figure 5h having been reduced in length by the selective removal of portions 68,70 shown in broken lines in Figure 5h.

The invention therefore provides a panel for use in a bathroom apparatus in the form of a bath or shower, and a method for adapting at least one dimension of the panel in an accurate manner so as to allow the panel to be changed to the required size for installation.