Abstract:
An apparatus and method for making a sloped floor includes a plurality of elongate arms disposed in radial array relative to a drain. Each arm has a common height along its extent. The radially innermost end of each arm is positioned near or connected to the drain. In a first embodiment, the radially innermost end of each arm is pivotally connected to an adapter that is connected to a center ring that circumscribes the drain. In a second embodiment, each arm is positioned at an incline by an adapter that rigidly joins the arm to the center ring. In a third embodiment, the arms are of shallow construction and are removed after the concrete has been poured. A mounting strip secured to the shower wall may support the radially outermost end of each arm. In all embodiments, the concrete is worked so that it is flush with the uppermost edge of each elongate arm.

Description:
BACKGROUND OF INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates, generally, to the construction arts. More particularly, it relates to an apparatus and method for making a sloped floor such as a shower floor.  
           [0003]    2. Description of the Prior Art  
           [0004]    U.S. Pat. Nos. 6,088,984 and 6,155,015 to the present inventor represent the prior art most relevant to the present invention. Those patents disclose apparatus and methods, respectively, for making a sloped floor, such as a shower floor, by positioning a plurality of elongate arms in radial array about a center ring that circumscribes a shower drain, Each arm has a flat bottom edge that rests atop a pitched or unpitched floor surface. Each arm has a sloped upper edge that determines the slope of the shower floor when the installation is completed. The height of each arm is relatively low at its radially innermost end where it connects to the center ring and is relatively higher at its radially outermost end where it abuts the vertical walls of the shower stall. Thus, when concrete is poured into the shower stall and screed so that it is flush with the uppermost edges of the arms, the resulting slope is predetermined by the arms. This eliminates the need to form the slope by more involved methods and enables an unlimited number of shower floors to be constructed with a common ideal slope.  
           [0005]    The earlier system works well and has no substantial shortcomings.  
           [0006]    Accordingly, in view of the prior art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how further innovations could be provided.  
         SUMMARY OF INVENTION  
         [0007]    The new, useful, and nonobvious invention of this disclosure enables the construction of a sloped floor with elongate arms that have a common height throughout their extent. The radially innermost end of each elongate arm may be attached to any part of a drain structure or to a center ring that circumscribes a drain. In a first embodiment, the slope of each elongate arm is adjustable by turning a setscrew positioned near a radially innermost end of the arm. In a second embodiment, a clip having a predetermined angular orientation is secured to a center ring and the radially innermost end of each arm is secured to the clip. The clip holds the arm so that the radially outermost end of the arm is elevated with respect to its radially innermost end, with the angle of slope being determined by the structure of the clip. In a third embodiment, each arm has a shallow construction so that it is removable from the cement after the floor has been poured. In a fourth embodiment, the radially outermost ends of the arms are secured to a fastening means that circumscribes the shower stall.  
           [0008]    A primary object of the invention is to provide a method and apparatus for facilitating the installation of a sloped floor such as a shower floor.  
           [0009]    Another closely related object is to enable such installation using elongate arms of uniform height.  
           [0010]    These and other important objects, advantages, and features of the invention will become clear as this description proceeds.  
           [0011]    The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0012]    For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:  
         [0013]    [0013]FIG. 1 is a top plan view of a shower floor depicting the elongate arms having their respective radially innermost ends connected to a center ring that circumscribes a drain;  
         [0014]    [0014]FIG. 2 is a top plan view of a first embodiment of a center ring;  
         [0015]    [0015]FIG. 3 is a perspective view of the center ring depicted in FIG. 2;  
         [0016]    [0016]FIG. 4 is a top plan view of a second embodiment of the center ring;  
         [0017]    [0017]FIG. 5 is a perspective view of the center ring depicted in FIG. 4;  
         [0018]    [0018]FIG. 6 is a side elevational view of a first embodiment of an elongate arm of uniform height along its extent;  
         [0019]    [0019]FIG. 7 is a top plan view of the arm depicted in FIG. 6;  
         [0020]    [0020]FIG. 8 is a side elevational view of a means for pivotally interconnecting an elongate arm to the center ring;  
         [0021]    [0021]FIG. 9 is a top plan view of the means of FIG. 8;  
         [0022]    [0022]FIG. 10 is a front end view of the means of FIG. 8;  
         [0023]    [0023]FIG. 11 is a perspective view of the means of FIG. 8;  
         [0024]    [0024]FIG. 12 is a side elevational view of the arm of FIGS. 6 and 7 disposed in interconnected relation to the means of FIGS.  8 - 11  when said arm is in a horizontal disposition;  
         [0025]    [0025]FIG. 13 is a side elevational view of the arm of FIGS. 6 and 7 disposed in interconnected relation to the means of FIGS.  8 - 11  when said arm is in a sloped disposition;  
         [0026]    [0026]FIG. 14 is a side elevational view of a second embodiment of the elongate arm;  
         [0027]    [0027]FIG. 15 is a top plan view of the arm depicted in FIG. 14;  
         [0028]    [0028]FIG. 16 is a top plan view of a means for interconnecting the radially innermost end of an elongate arm to the center ring of FIGS. 4 and 5;  
         [0029]    [0029]FIG. 17 is a front end view of the means depicted in FIG. 16;  
         [0030]    [0030]FIG. 18 is a side elevational view of the means depicted in FIG. 16;  
         [0031]    [0031]FIG. 19 is a perspective view of the means depicted in FIGS.  16 - 18 ;  
         [0032]    [0032]FIG. 20 is a perspective view of a third embodiment of the elongate arm;  
         [0033]    [0033]FIG. 21 is a perspective view of a telescopically constructed version of the elongate arm of FIG. 20;  
         [0034]    [0034]FIG. 22 is a side elevational view depicting the elongate arm of FIG. 20 or  21  adapted for pivotal connection to the connector of FIGS.  8 - 11 ;  
         [0035]    [0035]FIG. 23 is a plan view of an embodiment of the elongate arm having a bulbous radially innermost end;  
         [0036]    [0036]FIG. 24 is a side elevational view depicting an alternative means for elevating a radially outward end of an elongate arm;  
         [0037]    [0037]FIG. 25 is a top plan view of a third embodiment of the center ring; and  
         [0038]    [0038]FIG. 26 is a side elevational view of an elongate arm adapted to engage the center ring of FIG. 25. 
     
    
     DETAILED DESCRIPTION  
       [0039]    Referring to FIG. 1, it will there be seen that the reference numeral  10  denotes an illustrative embodiment of the present invention installed in a shower stall  12  or other room having a floor  14  that slopes to a drain  16 .  
         [0040]    A plurality of arms  18  of elongate construction is depicted in radial array relative to drain  16 . The radially innermost end of each arm  18  is positioned contiguous to drain  16  but need not be attached thereto. However, unwanted movement of said arms can be prevented by securing the radially innermost ends to a part of the drain. For example, said radially innermost ends may be secured to the body of the drain, the frame, the riser, the strainer, or any other related part of the drain.  
         [0041]    In the preferred embodiment of this invention, the radially innermost ends are secured to center ring  20 . Said center ring  20  is positioned in circumscribing relation to drain  16 , preferably in concentric relation therewith.  
         [0042]    [0042]FIG. 2 depicts center ring  20  in plan view and FIG. 3 provides a perspective view thereof. A plurality of blind cylindrical bores, collectively denoted  22 , is formed in center ring  20  in circumferentially and equidistantly spaced relation to one another. Each blind bore has a radially outermost section in open communication with the outer peripheral edge of center ring  20  as perhaps best understood in connection with FIG. 3.  
         [0043]    An alternative embodiment  20   a  of center ring  20  is depicted in FIGS. 4 and 5. The blind bores  22   a  of this embodiment are also circumferentially and equidistantly spaced apart from one another, but instead of having a cylindrical cross-section, their respective cross-sections have a generally “T”- shaped configuration. The base of each bore is in open communication with the outer peripheral edge of center ring  20   a.    
         [0044]    A side elevational view of an arm  18  is provided in FIG. 6. In this embodiment, an unnumbered truss-like structure provides the needed strength while saving materials and reducing the weight of the arm. The upper edge of arm  18  is denoted  19 . When concrete is poured to complete the sloped floor, it is made flush with upper edge  19 . Thus, the rest of arm  18  is permanently embedded in the concrete.  
         [0045]    As perhaps best understood in connection with FIG. 7, a transversely disposed peg or pivot pin  24  is formed in the leading end of arm  18 . As best indicated in FIG. 6, beveled surface  26  is formed in said arm just to the rear of said pivot pin. Cylindrical throughbore  28  has a lowermost or leading end in open communication with beveled surface  26  and the longitudinal axis of the throughbore is perpendicular to said beveled surface  26 .  
         [0046]    It should also be noted at the right hand end of FIGS. 6 and 7 that the trailing end of arm  18  is adapted to engage the leading end of an auxiliary arm  18   a  (FIG. 1) of similar construction to thereby effectively lengthen arm  18  in those applications requiring arms of greater extent. FIG. 1 depicts auxiliary arms  18   a  having their respective leading ends releasably engaged to the respective trailing ends of arms  18 .  
         [0047]    Connector  30 , depicted in FIGS.  8 - 11 , interconnects the leading or radially innermost end of an arm  18  to center ring  20 . There is a plurality of said connectors connected to center ring  20  in circumferentially spaced relation to one another. Each connector  30  has a radially innermost part  32  that fully occupies an associated blind bore  22  of center ring  20  when the novel apparatus is assembled. The cylindrical cross-section of said part  32  is depicted in the plan view of FIG. 9. The opposite ends of pivot pin  24  (FIGS. 6 and 7) are pivotally supported in the respective rounded bottoms  32   a ,  32   b  of vertical slots  34   a ,  34   b , formed in upstanding sidewalls  36   a ,  36   b  of connector  30  when the leading (radially innermost) end of arm  18  is positioned in sandwiched relation between said upstanding sidewalls  36   a ,  36   b.    
         [0048]    An imperforate bearing wall  38  interconnects sidewalls  36   a ,  36   b , as perhaps best understood in connection with FIGS. 9 and 11.  
         [0049]    As best understood in connection with FIGS. 12 and 13, beveled surface  26  (FIG. 6) of arm  18  overlies bearing wall  38  when arm  18  is in repose. Note that an unnumbered gap exists between beveled surfaces  40   a ,  40   b  and beveled surface  26  when said arm  18  is in repose. The slopes of the mating beveled surfaces are preselected so that arm  18  is sloped toward the center ring or drain at a quarter inch per foot when said arm is in said position of repose. Accordingly, if concrete were poured into the shower area and screed to the level of upper edge  19 , the resulting floor would have a quarter inch per foot slope. However, there is no requirement that this minimum slope be built in. It is also within the scope of this invention to form the mating beveled surfaces so that arm  18  is horizontal when in repose. The user would then be required to slope the arm in the manner hereinafter to be described. Even if a quarter inch slope is built in, the following steps are required to increase the slope if desired.  
         [0050]    To impart additional slope to arm  18  and hence to upper edge  19  thereof, setscrew  29  is advanced in setscrew bore  28  so that its leading end bears against bearing wall  38 . The unnumbered gap appearing in FIG. 12 decreases in size and disappears as setscrew  29  is advanced further and further until said setscrew is fully advanced as depicted in FIG. 13. Simultaneously, an unnumbered gap appears between beveled surface  26  of arm  18  and bearing surface  38  of connector  30 . The radially innermost end of arm  18  is now disposed between upstanding beveled surfaces  40   a ,  40   b  formed in sidewalls  36   a ,  36   b . This imparts a maximum slope to arm  18  and hence upper edge  19  thereof. Thus, any intermediate degree of slope is attained by advancing the setscrew an appropriate distance between its unadvanced and fully advanced positions, there being an infinite plurality of functional positions of adjustment between the in-repose position of FIG. 12 and the fully inclined position of FIG. 13.  
         [0051]    An optional auxiliary screw  17  is screw threadedly, slidingly, or otherwise adjustably engaged in a bore formed in a radially outermost end of arm  18  as depicted in FIG. 13. However, screw  17  could also be positioned radially inwardly relative to said radially outermost end and still perform the same function. Screw  17  supports said radially outermost end, but it may be eliminated from the novel apparatus without significant detriment to the system.  
         [0052]    A second embodiment of elongate arm  18 , denoted  18   a  in FIGS. 14 and 15, is adapted at its radially innermost end to engage connector  42  of FIGS.  16 - 19 . Specifically, a “T”-shaped connector  21  is formed in said radially innermost end. Connector  42  has a “T”-shaped radially innermost part  44  that engages an associated “T”-shaped bore  22   a  formed in center ring  20   a  of FIGS. 4 and 5. Connector  42  further includes a “T”-shaped bore  46  formed in its radially outermost end. Bore  46  slidingly receives “T”-shaped connector  21  formed in the radially innermost end of arm  18   a . Significantly, a slope is imparted to arm  18   a  because bore  46  is canted relative to a vertical plane at a predetermined angle that is hard to see in the Figure but which should be understood as being present.  
         [0053]    Rod  50  of FIG. 20 has a triangular cross-section. It may be formed of aluminum, stainless steel, plastic, metal-containing plastic, or other suitably stiff and durable material.  
         [0054]    As indicated in FIG. 21, rod  50   a  may have a telescopic construction. Thus, in an application where rod  50  has insufficient length, rod  50   a  is advantageously used. The user merely extends rod  50   a  to the desired extent and tightens setscrews  51  to maintain the proper length when said proper length has been found.  
         [0055]    Unlike arms  18  and  18   a , rod  50  or  50   a  has a very shallow construction. In a preferred embodiment, the uniform height of rod  50  or  50   a  is about one-quarter inch. Thus, when concrete is poured and worked until it is flush with the flat top wall of arm  50  or  50   a , it is easy to retrieve said arm so that it is not embedded in the floor. A shallow “V”-shaped groove remains in the floor, but such groove is filled if needed and covered by tile when the installation is complete.  
         [0056]    The radially innermost end of rod  50  or  50   a , like arms  18  and  18   a , may be attached to a center ring such as center ring  20 , for example, or it may be attacked to a preselected part of drain  16 , or it may be positioned near said drain but not attached thereto.  
         [0057]    As indicated in FIG. 22, rod  50  or  50   a  may be connected to center ring  20  by the same coupler  30  depicted in FIGS.  8 - 11 . Alternatively, many different types of couplers could be used to pivotally attach the radially innermost end of rod  50  or  50   a  to said center ring.  
         [0058]    However, the desired pivotal connection may also be made in the absence of a coupler because the radially innermost end of rod  50  or  50   a  could be directly pivotally coupled to said center ring. For example, a bulbous means  53  is formed on the radially innermost end of a rod  50  or  50   a  as depicted in FIG. 23. Bulbous means  53  forms a ball suitable for connection to a socket of the type formed in center ring  20  of FIGS. 2 and 3. Numerous ways could then be provided to impart a slope as desired to such rod. Any height-adjustment means, such as but not limited to screw  17  of FIG. 13, could be employed, for example. A ratchet and pawl mechanism could be provided as well, as a part of the ball and socket interconnection, so that the slope could be adjusted simply by lifting the radially outermost end of the rod. An adjustable height means could be employed in conjunction with such a ratchet and pawl arrangement.  
         [0059]    The radially outermost end of arm  18 ,  18   a , or rod  50 ,  50   a  may also be advantageously secured to a mounting means secured to the shower wall that is elevated with respect to the drain by a predetermined amount. As depicted in FIG. 24, mounting means  52  is preferably provided in the form of a bracket or strip of material that is mountable by suitable means to shower walls  12   a ,  12   b ,  12   c , and  12   d  (FIG. 1). It may have a channel or “J” shape as depicted, or any other functional shape. Thus, the radially outermost end of an arm  18 ,  18   a , or rod  50 ,  50   a  is easily secured to said strip  52  and the desired slope is thereby established. The installer must position bracket  52  at a proper elevation relative to shower floor  14  to achieve the desired angle of slope.  
         [0060]    In the alternative, the radially outermost end of arms  18 ,  18   a , or rods  50 ,  50   a , may be supported by adjustable height means such as screw  17  in FIG. 13 or mounting strip  52  in FIG. 24. Said radially outermost ends may also be unsupported. In such event, the arm or rod is supported at a preselected slope by the means for coupling the arm or rod to the center ring or the drain.  
         [0061]    Neither arms  18 ,  18   a , nor rod  50 ,  50   a  has the tapered construction of the arms of the prior art. Such arms and rods are thus easier and less expensive to manufacture than the tapered arms. Moreover, the means disclosed herein for positioning said arms and rods at various predetermined angles to create sloped floors further advances the construction arts in a substantial way.  
         [0062]    A circular slot  22   b  is formed in center ring  20   b  of FIG. 25 in substantially concentric relation therewith. Slot  22   b  is slideably engageable by any of the elongate arms of this invention, not just elongate arm  50  as depicted. Any suitable engagement means such as elbow  53   a  may be employed. Elbow  53   a  may be hingedly mounted to an elongate arm so that the angle between said elongate arm and said elbow is adjustable to any degree of slope that may be required to complete a sloped floor in accordance with the teachings of this invention. As in the earlier-described embodiments, all other means for changing the angle between such elbow and the elongate arm are within the scope of this invention, including ratchet and pawl mechanisms, setscrews, couplers such as those depicted in FIGS.  16 - 19 , means for holding the radially outermost end of the elongate arm at a predetermined elevation such as depicted in FIG. 24, and so on. Moreover, any attachment means that is slideably disposed within circular slot  22   b  is within the scope of this invention, not just elbow  53   a.    
         [0063]    Advantageously, circular slot  22   b  enables elongate arms such as  18 ,  18   a ,  50 ,  50   a  to be positioned in infinitely many functional angles of radial adjustment relative to center ring  20   b . Moreover, the cementitious material used to complete the sloped floor cannot enter into slot  22   b ; note that such material can enter into openings  22  of center ring  20  and openings  22   a  of center ring  22  because such openings are in open communication with the exterior surface of center rings  20 ,  22 . Thus, if a center ring is re-used, openings  22  or  22   a  must be cleaned out prior to re-use. No such cleaning is required when center ring  20   b  is used.  
         [0064]    It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.  
         [0065]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.  
         [0066]    Now that the invention has been described,