This invention relates to building a shower base and the correct way to achieve that result. In a shower, the drain is normally in the approximate center of the space that is enclosed by the shower. In order to avoid the pooling of water in the shower space the floor surface should be slightly sloped so that the water in the shower will naturally drain towards the location of the shower drain. If the shower floor surface does not have this slope, the water will pool in the shower space and this pooling may become a hazard for persons using the shower as well as providing an incubator for mold and mildew in the shower.
In the installation of a shower floor, the drain is usually set first in the shower floor surface and then floor mud is poured around it. Floor mud is the base for ceramic tile or another material installed on top of floor mud later. A screed, which is a common tool, is used to form the floor mud surface around the drain area to ensure the appropriate slope that is required. In addition to the use of the screed to form the floor mud and provide the slope, the screed also ensures that the surface of the shower floor mud is smooth. In order to create a correct, shower floor mud surface, it is required that the screed slides on top of a rigid structure with a desired shape, which determines the the screed. This device represents one of the embodiments of such supportive structure.
There are prior art references on how to form a shower floor mud and a sample of this can be found in Rossi U.S. Pat. No. 6,848,229 B2. Besides other differences, this device is substantially and methodologically different from the operation of this particular device that has been filed in this case, because the referenced prior art device is not producing a uniform slope around the shower floor area if the drain is placed other than in the center of a shower floor and/or if a shape of a shower floor is not square.
It is important to have a uniform slope so that the water drains properly, which thereby reduces the likelihood of injury in the shower caused by the pooling of water or excessive slope. Providing a uniform slope is also in line with construction codes and likely in line with the aesthetical requirements of a customer.
One of the important parts of the shower floor building process is in making a specially designed shape of the shower floor. There are certain functional and cosmetic considerations in the installation of a shower floor. Often the functional considerations will also address the cosmetic concerns.
With regard to cosmetic concerns the shower floor surface should appear to be without any obvious undesired raised or lowered surfaces. This obviously requires a smooth surface and the experienced craftsman will insure that the surface is smooth. However, the surface should also provide a slight slope so that the water in the shower goes in the direction of the drain. There are building codes that dictate the amount of the slope that is required. Compliance with the building codes are mandatory.
Typically, the foundation of a house is concrete and the area around a shower is designated. In a shower floor, the drain is usually placed in the general middle of this surface and slightly elevated from the concrete surface. Shower floor mud is then placed over the shower floor around the drain. It is shower floor mud that forms the shape of the floor of the actual shower. Any shower floor surface such as ceramic tile is placed on top of the shower floor mud when the shower floor is mainly compete.
The skilled craftsman uses tools, which are called a screed, and other construction tools such as a torpedo level, 2 or 4 foot levels, flat trowels and other construction hand tools to build the shower floor mud and provide a slope to the shower drain. The forming of the shower floor mud surface can be tedious and time consuming even for the most experienced craftsman.
Unfortunately, many shower floors do not meet the requirements of the construction codes and either produce pooling of the water in the shower area or an inappropriate cosmetic appearance, both of which are unacceptable. When a shower floor does not meet the code requirements, several different problems may arise. An example of some problems are the shower floor may hold water and allow mold growth against the wall surface. Accordingly, the wall and the structure around the wall will deteriorate over time. Moreover, the floor surface is not safe for the consumers because of the increased risk of slip and fall.
The device that is described in this application is designed to solve these issues with a simple to use tool and process to create the same uniformed slope at any point of a shower floor. When this device is used properly, the use of the tool will save time and money while producing a superior product that is both compliant with the appropriate building codes, as well as being functional and aesthetically pleasing to the consumer.
There are five main elements to this particular patent application: screed rings, segment(s) of the screed ring, screed edges, slope guide and screed tool.
In this first embodiment, this device is comprised of: a first screed ring 5, a second screed ring 10, and a slope guide 30. A screed ring is a rigid ring-shaped element with a predetermined shape which has a top edge which is commonly referred to as a screed edge 20. During the use of this device, a first screed ring 5 and a second screed ring 10, each having different desired radiuses and being placed on different horizontal planes, are located and placed on the shower floor mud 75. Such as depicted in
The geometric centers of the screed rings are located on the same vertical axis Z, (
It is anticipated that this device may be alternatively comprised of a first screed ring 5 and at least one segment 15 of a second screed ring.
Both the first screed ring 5 and the segment of the second screed ring 15 have a screed edge 20, which is shown in
The segments 15 of the screed ring are a plurality of rigid ring-shaped portions of a screed ring that can be used as single segments or interconnected together to form a partial or complete screed ring. Different sized desired diameter screed rings can be formed and used in the installation of a shower floor mud surface 75. The segments of the screed ring 15 can either be attachable to each other or not attachable to each other such as depicted on
The slope guide 30, which is shown in
The long side middle axis of the Slope Guide 30 also goes through the vertical axis “Z” and under 90 degree angle to it, when this device is installed correctly. Ring Grooves can be specially designed and not round. In this case, the long side middle axis of the Slope Guide 30 goes through the vertical axis “Z” and under 90 degree angle to it, when the device is installed correctly.
The dimension F, which is shown in
When the device is installed properly, the desired dimension H, which is shown in
The plurality of holding screws 55, which is shown in
In an alternative embodiment, the slope guide 30 may be modified such as depicted in
The slope guide 30 may also incorporate a vertical pole 70 (
It is also anticipated that the slope guide 30 can also be used as a screed tool 80.
This device is usable with at least two ring-shaped screed elements with different desired geometric radiuses and temporarily or permanently embedded to the shower floor mud 75 with the desired location and orientation.
The geometric centers of all ring-shaped elements are located on the vertical axis Z, which passes through the geometric center of a shower drain 1. The screed edge 20 of each screed element is located on its own horizontal plane with a desired distance between those two planes in a vertical direction and with the desired difference between the geometric radiuses of two elements.
The screed rings are embedded into the shower floor mud 75 for the purpose of creating support for the screed tool 80 (
There are four methods by which the device may be used. All four methods create a desired uniform slope to a drain 1 with a desired smooth surface of the shower floor mud 75.
In the first method, only screed rings of the device are used: the first screed ring 5 and the second screed ring 10. This method is used when the entire area of the shower floor could be done at the same time and a tradesman is able to install the screed rings correctly without using the slope guide 30 and with traditional tools available. The first method is to place mud 75 on the shower floor and then position the screed rings on top of it, where the first screed ring 5 (small ring) is at the center of the second screed ring 10 (big ring) and the shower drain 1 is at the center of the first screed ring 5. The screed edge 20 of the second screed ring 10 is desirably higher than the screed edge 20 of the first screed ring 5. The screed edge 20 of the first screed ring 5 is desirably below the top surface of the shower drain 1. The top edge/screed edge of the second screed ring 10 and first screed ring 5 are in two different horizontal planes, with a desired distance between those planes. After both rings are correctly installed and securely positioned inside the floor mud 75, a tradesman drops more mud 75 on top of the rings and around. At this point the mud should be pressed down/“packed” by a flat shape tool before the excess of the floor mud 75, which is above the screed rings, is removed/“shaved off” with a screed tool 80. The desired distance between the screed edges of the second screed ring 10 and first screed ring 5 in the radial direction, and the desired difference between the altitudes of the screed edges 20 of both screed rings determines the correct uniform slope of the floor mud 75 surface at any point of shower floor. When both rings are disposable, they can be left inside the floor mud 75. The reusable screed rings should be removed and the empty gaps of floor mud surface left from the removed screed rings should be filled with an extra portion of the floor mud 75 and the surface of the floor mud 75 should be finished/“ironed” with a flat shaped tool. Once the shower floor mud 75 is finished, the shower floor mud job is considered done.
In the second method, the following elements of the device are used: the first screed ring 5, the segment of the second screed ring 15, and the slope guide 30. This method should be used when, a mud job is performed section by section, or when the shower drain is close to a wall of a shower and a full screed ring cannot be used. After all elements are assembled together, a slope guide 30 and the floor mud 75 is placed on the shower floor. The device is placed on top of the floor mud 75 with the shower drain 1 located at the center of the first screed ring 5. Then, the slope guide 30, with all elements attached, is pressed into the floor mud 75 until the top surface of the slope guide 30 is horizontal and the screed edge 20 of the first screed ring 5 is located below the top of the drain 1 at the desired distance and level/horizontal. The second screed ring segment 15 should also be level/horizontal. The slope guide 30, thereby automatically generates the desired distance between the screed edges 20 of the first screed ring 5 and the segment of the second screed ring 15 in vertical and horizontal radial directions. Also, when the top surface 35 of the slope guide 30 is horizontal, the slope guide 30 ensures the correct horizontal position of both screed elements of the device. After the device is correctly assembled and the elements are securely positioned inside floor mud 75, the slope guide 30 is then unattached and removed.
The user then places more shower floor mud 75 on top of the designated area of the shower floor. The shower floor mud 75 should be packed down by a flat shape tool before the excess of the shower floor mud 75 is removed or “shaved off” with a screed tool 80. The first screed ring 5 and first segment of the second screed ring 15 are temporarily left inside the mud in a first section of the shower floor area. A second screed ring segment 15 of the second screed ring is attached to the slope guide 30. Then both of them are installed on top of the mud in the second section. For instance, in the opposite direction of the shower floor area, where the shower floor mud 75 was just installed.
If the drain 1 is close to the wall the “second section” will be located next to the “first section”, which is already made. In this case, a doubled screed ring segment 15 (half of the ring) can be used, if necessary.
The screed edge 20 of the first screed ring 5, which was already implanted into the shower floor mud 75, is then placed into the first screed rings groove 40 of the slope guide 30. After being correctly located, the slope guide 30 is pressed into the floor mud 75 until the top screed edge 20 of the first ring 5 touches the bottom of the related ring's groove 40 and until top surface 35 of the slope guide 30 is substantially horizontally level. The slope guide 30 automatically secures the desired location and orientation of the second segment 15 of the second screed ring. After the second segment 15 of the second screed ring is firmly secured into floor mud 75, the slope guide 30 is then unattached and removed. A tradesman or other user would then place more shower floor mud 75 on top of the second section of the working area of the shower floor area. Then the shower floor mud 75 should be pressed or packed down by a flat shaped tool before excess of the shower floor mud 75 is removed or shaved off with a screed tool 80. Then, two additional segments 15 of the second screed ring can be installed. When two segments of the second screed ring 15 are already implanted in two opposite sections of a shower floor with the help of a slope guide 30, the other two sections 15 of the second screed ring 10 can be installed without the slope guide 30 manually. Those two can be implanted into the shower floor mud 75 with “bare hands” and with the same shower floor mud 75 operational procedure. Before the excess of the floor mud 75 is shaved off by the screed tool 80, the top edges of the previously installed ring segments should be lined up in a horizontal plane with the top edges of the freshly installed (manually installed) ring segments 15, and connected or overlapped over each other.
After all four areas of the shower floor are done, the disposable elements can be left inside the shower floor mud 75. The reusable elements must be removed, and the empty gaps are filled with mud. The mud on the surface of the floor is then fixed, (“ironed”) by a flat shape tool. The shower floor mud job is now considered finished. The user may utilize level adjusters, when he uses the slope guide 30. Also, the user can use a vertical pole, in order to use the alternative way to verify the level of the top surface of the slope guide 35, when he installs the device.
With the third method, the following elements of the device are used: first screed ring 5, a second screed ring 10, and a slope guide 30. This method is used when the entire area of the shower floor could be done at the same time. This method is similar to the first method, where the slope guide 30 was not used. This method uses a slope guide 30 in order to make this method more effective and easier than the first one. The slope guide 30 automatically secures the correct location and orientation of first screed ring 5 and second screed ring 10, and therefore simplifies and speeds up the process and increases the level of precision. After all of the elements are assembled together and the shower floor mud 75 is placed on the floor, the device is placed on top of the shower floor mud 75 and the shower drain 1 is located at the center of a first screed ring 5. Then the slope guide 30, with all of the elements attached, is pressed into the shower floor mud 75 until top surface of the slope guide 35 and screed edge 20 of the first screed ring 5 and the second screed ring 10 are level/horizontal; the screed edge 20 of the first screed ring 5 is located below the top surface of the shower drain 2 at the desired distance. The slope guide 30 ensures the desired distance between the screed edges 20 of the first screed ring 5 and the second screed ring 10 in vertical and in horizontal radial directions. After the device with the elements are correctly installed and the elements are firmly implanted/secured into the shower floor mud 75, the slope guide 30 is then unattached and removed, only if the slope guide 30 is reusable. Then user/operator drops more shower floor mud 75 on top of the “working” area. Then the mud should be pressed down/“packed” by a flat shape tool before the excess of the floor mud is removed/“shaved off” with a screed tool 80. The disposable elements can be left inside the shower floor mud 75. When the reusable elements are removed, the empty gaps are filled with shower floor mud 75, and the surface of the floor mud is fixed/“ironed” by a flat shape tool. The shower floor mud job is now considered finished. The device created a smooth shower floor mud 75 surface with correct uniform slope to the shower drain 1 at any point of a shower floor area. The user may utilize level adjuster(s) 60 (
With the fourth method, more than three elements of the device are used: first screed ring 5, second screed ring 10, and more than one slope guides 30. This kind of device or element can be disposable or reusable. The device with more than one slope guides 30 would be preferably used when level adjusters 60 are present and used. At least one level adjuster 60 per each slope guide 30 can be used. The lever adjuster(s) 60 can be used when surface of the shower pan is fairly good, decently level and has no significant defects. With the level adjusters 60 the operator can install the device on top of the shower pan first and then drop the shower floor mud 75 on top of the device and around. This method is similar to the third method with the differences that, in this case, the device has more than one slope guide 30 and the device is installed on the shower pan first and then the shower floor mud 75 is dropped on top and around. The entire device can be made as a solid mold, made by other different way structure, or it can be easily assembled from more than one molded or made by other different way sections. In this case the device can be located in the shower pan and then the mud work is performed. Alternatively, for both reusable and disposable versions, the floor mud can be dropped first, and then the device can be placed on top of the shower floor mud 75.
In the following step, the device is placed in the bottom of the shower pan with the drain 1 located at the center of a first screed ring 5, then by rotating the level adjusters 60 in the required direction, the tradesman achieves the desired orientation in the 3D space of all the elements of the device. The top surface of all slope guides 35 should be level/horizontal. As long as the slope guides 35 are level, the screed edges 20 of both rings will be level/horizontal automatically. The screed edge 20 of the first screed ring 5 should be lower than the top surface of the drain 1. The slope guide 30 thereby automatically ensures the desired distance between the screed edges 20 of the first screed ring 5 and the screed edge 20 of the second screed ring 10 in vertical and horizontal radial directions. After the device is correctly installed the user/operator drops the shower floor mud 75 on top and around the device. After the first screed ring 5 and the second screed ring 10 are firmly secured inside the shower floor mud 75, the slope guides 30 can be unattached and removed, if the slope guides 30 are reusable. Then the user/operator drops more shower floor mud 75 on top of the “working” area. Then the shower floor mud 75 should be pressed down/“packed” by a flat shape tool before the excess of the shower floor mud 75 is removed/“shaved off” with a screed tool 80. The device creates a smooth shower floor mud 75 surface with the correct uniform slope to the shower drain at any point of the shower floor. If some elements of the device or the entire device is disposable, then those elements of the device or the entire device can be left inside the shower floor mud 75. The reusable elements are removed, and the empty gaps are filled with shower floor mud 75 and the surface of the floor mud is fixed/“ironed” by a flat shape tool. The shower floor mud job is considered finished. If the slope guides 30 are disposable, it should be modified in the way that top surface of the slope guide(s) 35 are located at the same altitude as the screed edges 20, or lower. When level adjusters 60 are in use, at least one level adjuster 60 is required for each slope guide 30.
This device may be further comprised of a screed tool 80. A screed is the term used to describe a rigid object with a straight edge that is drawn over freshly poured concrete/mud on top of specially designed rigid and stable support. The device described herein is a rigid buildup support for the screed and described in four separate embodiments. The shape of this support determines the shape of the shower floor mud 75 surface. The support is comprised of a plurality of screed elements. A screed element may be a first screed ring 5, a second screed ring 10, or a segment of a screed ring 15. A screed edge 20 is a top edge of each of the screed elements of the device that are in contact with a screed tool 80 while in use. When the screed tool 80 is moved on top of a screed edge 20 of the screed elements, it forms the desired uniformed slope and shape of the shower floor mud 75 surface by removing the excess of the mud, which is above those elements of the device. The mud 75 which is left below the screed edges 20 is formed with the desired and required shape. In some instances, the slope guide 30 can be used as a screed tool 80.
In all methods, with use of the Slope Guide 30, operator has an option not to remove Slope Guide(s) 30 before screeding process. Screed can be done in all shower floor area, where it's possible, then entire assembled device (Rings and Slope guides) can be removed from the shower floor mud 75, and then additional portion of the floor mud 75 can be filled up in empty/hollow spaces left by the device's elements.
The present nonprovisional patent application is a continuation of nonprovisional patent application Ser. No. 16/025,623 filed on Jul. 2, 2018 and claims the benefit of the filing date under 35 U.S.C. § 119(e) of Provisional Patent Application Ser. No. 62/527,669 filed on Jun. 30, 2017.