Abstract:
In recent decades within the building industry, there has been a trend toward mass production of building components. The trend has included every part of structures except for the concrete slab the building is built on. The “Threshold Tray and Clip System” uses mass-produced products to be applied to construction of slabs and foundations, allowing sill steps to be built in rough openings with pre-fabricated form parts. The forms remain in the concrete and are permanent. This means that consistent results can be expected. Other mass-produced products, such as door systems, will fit into rough openings more accurately. Over-all quality of the structure will be increased.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     “Not Applicable” 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     “Not Applicable” 
       REFERENCE TO SEQUENCE LISTING  
       [0003]     “Not Applicable” 
       BACK GROUND OF THE INVENTION  
       [0004]     Hurricane Andrew came through south Florida with such fury that it illuminated the need for door entry systems and glass doors in residential and small commercial construction to be reinforced against blow-in. The construction industry modified its practice of mounting door entry systems and sliding glass door units, used in slab construction, directly on the slab. The “new method” in use, is to cast a step into the slab using a piece of lumber. The step is normally cast using a nominally dimensioned piece of lumber, resulting in a step that is one and one-half inches deep and five and one-half to nine and one-half inches in width. The lumber is removed after the concrete sets. The entry system or sliding glass-door frame is set into the pocket of the step in the slab.  
         [0005]     The use of warped or split lumber, improperly positioned or secured lumber, and destruction of the concrete edge when removing the lumber form, are some of the practices that result in non uniform step dimensions. Considerable time and effort is expended in some cases to repair the step. Manufacturers cannot be sure that their doors will meet design strength when installed in uneven openings. Therefore, I have conceived “The Threshold Tray and Clip System” to fill a need in the commercial and housing building industry.  
       BRIEF SUMMARY OF THE INVENTION  
       [0006]     The “Threshold Tray and Clip System” is comprised of a tray and three clips. The tray, slightly less than one foot in width, four inches in depth, and ten feet in length, is a sheet of suitable material, formed into a Z cross sectional shape. The clips mount the tray to the block foundation-wall commonly found in residential and light commercial slab construction. The “Threshold Tray and Clip System” is a form that remains in the concrete slab after cure.  
         [0007]     When the “Threshold Tray and Clip System” is used in slab construction, it results in a finished, uniform, and dimensionally correct reinforced step in the slab at a rough opening. The “Threshold and Clip System” requires nothing beyond simple installation, and is a labor saving method of step construction. It allows the door vendors to correctly install doors, insuring the door manufacturers that their doors will meet local blow-in code requirements. 
     
    
     DESCRIPTION OF DRAWING VIEWS  
       [0008]      FIG. 1 . This is a view of a TRAY with the inside of the TRAY facing the viewer. This view shows the TRAY in an upright position.  
         [0009]      FIG. 2 . This view shows the TRAY in an upside down position with the outside of the TRAY facing the viewer.  
         [0010]      FIG. 3 . This is a view of a CLIP.  
         [0011]      FIG. 4 . This is a view of the CLIP from the opposite viewing angle.  
         [0012]      FIG. 5 . The CLIP in this view is shown with the dimensions that are relevant to the invention.  
         [0013]      FIG. 6 . This view shows a shortened TRAY with the dimensions relevant to this invention.  
         [0014]      FIG. 7 . In this view, a CLIP is set on a masonry chair-block in the position that places it at the left side of a rough opening in a foundation wall, as seen from outside the building.  
         [0015]      FIG. 8 . This view shows a CLIP set on a masonry chair-block in the position that places it at the right side of a rough opening in the foundation wall.  
         [0016]      FIG. 9 . This view shows a CLIP that is placed on a masonry half-high block in one of two positions that are used in the invention.  
         [0017]      FIG. 10 . This view shows a CLIP that is placed on a masonry half-high block in the second of two positions that are used in the invention.  
         [0018]      FIG. 11 . This view shows the rough opening with the CLIPS and masonry blocks set in mortar in the foundation wall. This view is seen from outside the wall.  
         [0019]      FIG. 12 . This view shows the same rough opening as shown in  FIG. 11 . This view is seen from inside the wall.  
         [0020]      FIG. 13 . This view shows the same rough opening, viewed at the same angle as shown in  FIG. 11 . In this view, the CLIPS have been bent to support and fix the TRAY  
         [0021]      FIG. 14 . This view shows the same rough opening, viewed at the same angle as shown in  FIG. 12 . In this view, the CLIPS have been bent to support and fix the TRAY.  
         [0022]      FIG. 15 . This view shows the same rough opening, with the same bends to the CLIPS, and from the same angle as  FIG. 13 . In this view, a TRAY with viewing cutouts has been placed in the rough opening. The relationship between the TRAY and the CLIPS in their various positions is shown in this view.  
         [0023]      FIG. 16 . This view shows the same rough opening as  FIG. 15 , except in this view the rough opening is seen from inside the wall.  
         [0024]      FIG. 17 . This view shows a completed installation of the THRESHOLD TRAY AND CLIP SYSTEM in the same rough opening as shown in  FIGS. 11 through 16 . The concrete floor has been poured and the TRAY has formed the step. This view is seen from out side the foundation wall.  
         [0025]      FIG. 18 . This view is of a TRAY section and a CLIP. It shows the positional relationship between the TRAY and a CLIP as if the CLIP were set on a masonry chair-block. The view is seen from underneath the TRAY section.  
         [0026]      FIG. 19 . This view is of the same TRAY and CLIP as shown in  FIG. 18 . This view is seen from above the TRAY section.  
         [0027]      FIG. 20 . This view is of a TRAY section and a CLIP. It shows the positional relationship between a TRAY and a CLIP as if the CLIP were set on a masonry chair block as shown in  FIGS. 7 and 8 . In this view, the CLIP locking-tab has been bent into its locking position to fix in place the end of the TRAY. This view is seen from above the TRAY section.  
         [0028]      FIG. 21 . This view is of the same TRAY section and CLIP as in  FIG. 20 . This view is seen from underneath the TRAY section.  
         [0029]      FIG. 22 . This view is of a TRAY section and a CLIP. It shows the positional relationship between a TRAY and a CLIP as if the CLIP were set on a masonry half-high block as shown in  FIG. 10 . The CLIP locking-tab has been bent into the alternate locking position to fix the front of the TRAY in place between the locking-tab and the face flange of the CLIP. The tray-support-tab of the CLIP has been bent in a position to support the TRAY. This view is seen from above the TRAY section.  
         [0030]      FIG. 23 . This view is of the same TRAY section and CLIP as shown in  FIG. 22 . This view is seen from underneath the TRAY section.  
         [0031]      FIG. 24 . This view shows the “Threshold Tray and Clip System” in an assembled condition with the top of the TRAY (reference character A) facing up.  
         [0032]      FIG. 25 . This view shows the assembly shown in  FIG. 24 , except that the assembly is rotated one-quarter turn so that the front of the TRAY (reference character C) is facing up.  
         [0033]      FIG. 26 . This view shows the assembly shown in  FIG. 24 , except that the assembly is rotated one-half turn so that the bottom surface of the TRAY (reference character B) is facing up. 
     
    
     THE LIST OF REFERENCE CHARACTERS  
       [0034]    
       
          A—The top surface of a TRAY.  
          B—The bottom surface of a TRAY.  
          C—The outside surface of the TRAY, also called the front of the TRAY.  
          D—The inside surface of the TRAY, also called the back of the TRAY.  
          E—The face-flange of a CLIP.  
          F—The locking-tab of a CLIP.  
          G—The mounting and locking-flange of a CLIP.  
          H The mounting and support-tab of a CLIP.  
          I—A masonry chair block.  
          J—A masonry half-high block.  
          K—The lower edge of the front (outside) of the TRAY.  
          L—The upper edge of the back (inside) of the TRAY.  
       
     
       DETAILED DESCRIPTION OF THE INVENTION  
       [0046]     The “Threshold Tray and Clip System” is comprised of two different manufactured parts that are supplied in various quantities to make up the total needed to construct a form that shapes the poured concrete floor of a building. The purpose of the form is to construct a step in the rough opening of exterior doorways that will accept the sill of exterior door systems and sliding-glass doors. The form stays in the poured floor and becomes part of the floor of the building. The TRAY part of the system is manufactured in lengths of 10 feet from 14 gauge galvanized steel sheet.  FIGS. 1 and 2  show a TRAY seen from different angles. TRAYS can be set end-to-end or cut to length on the job-site to fit any width of rough opening. The CLIP part of the system is stamped from 16 gauge galvanized steel sheet. The CLIPS are supplied in an original configuration that allows them to be hand bent on the jobsite to use two different methods of holding the TRAY.  FIGS. 3 and 4  show a CLIP seen from different angles.  
         [0047]     When the rough opening is built that will utilize the “Threshold Tray and Clip System” two styles of masonry block are required. The chair block as seen in  FIGS. 7 and 8 , and the half-high block as seen in  FIGS. 9 and 10 , are set with the chair blocks on the outside edges and the half-high blocks in the middle to form the width of the rough opening. A rough opening like the one described can be seen in  FIGS. 11, 12 ,  13 ,  14 ,  15 ,  16 , and  17 .  
         [0048]     The step in the rough opening has specific dimensions. The depth of the step is measured from the front (reference character C) of the TRAY to the front-side of the back (reference character D) of the TRAY. This dimension is 6 inches and is shown in  FIG. 5 . The height of the step is measured from the lower edge of the front surface (reference character K) of the TRAY to the top surface (reference character A) of the TRAY. This dimension is 2{fraction (1/2 )} inches and is shown in  FIG. 5 . The height of the floor above the step is measured from the top surface of the TRAY to the upper edge of the back surface (reference character L). This dimension is 1{fraction (1/2)} inches and is shown in  FIG. 5 . When the TRAY is set in the rough opening between the chair blocks, with the front face resting on the half-high blocks, flush with the outside of the half-high blocks, and the top surface on a horizontal plane, a step will be formed. The step will measure 6 inches deep by 1{fraction (1/2 )} inches lower than the floor. The width of the step will be whatever the building plan describes for that rough opening, which can be achieved by adding or subtracting half-high blocks and adding TRAYS or trimming the TRAY to fit. A view of a completed step is shown in  FIG. 17 .  
         [0049]     In order for the TRAY to become a form, it must be fixed in place in the rough opening while the concrete floor is poured. The CLIP is the form-locating device used in the “Threshold Tray and Clip System”. The CLIP connects the TRAY to the foundation wall. The CLIPS are mortared between the masonry blocks when the blocks are set. The block mason applies mortar to the block with a trowel in the normal way before placing the CLIP on the block. The CLIP is pressed to the mortar in the appropriate location. Then the block mason sets the block, straight and level, in the foundation wall.  FIGS. 7 and 8  show the approximate position the CLIP will have on a chair block at either end of the rough opening. When placed on the chair block the part of the CLIP that will be imbedded in mortar is the mounting and support tab (reference character H, in  FIGS. 3 and 4 ). The approximate position of a CLIP on a half-high block, when the half-high block is adjacent to a chair block is shown in  FIG. 9 . In  FIGS. 11 and 12 , the CLIPS that are located between a chair and half-high block are shown in their relative positions. In order for the TRAY to form the step at the correct height, the CLIP must be located accurately relative to the floor. To accomplish this the CLIP has a locating flange (reference character E in  FIGS. 3 and 4 ). The flange rests on the upper surface of the chair block, which is the same height as the floor surface. To see the relationship of a CLIP face flange, chair block, and floor in a finished installation, refer to  FIG. 17 .  FIG. 10  shows a CLIP placed on a half-high block in the position it occupies when two half-high blocks are adjacent. When placed on a half-high block in this location the part of the CLIP that will be imbedded in mortar is the mounting and locking flange (reference character G, in  FIGS. 3 and 4 ). Again, the face flange (reference character E) is used to locate the CLIP. The inside surface of the face flange should be set flush with the outer surface of the foundation wall. The relative position of the CLIP and the half-high block, when installed in a foundation wall can be seen in  FIG. 11 . When the mortar sets, the CLIPS will be firmly locked in the foundation wall.  
         [0050]     In order that the CLIPS hold the TRAY in the correct position, tabs on the clips must be bent to accommodate the tray. These tabs, and the spaces between them must be manufactured to specified dimensions. The dimensions of the CLIP relevant to this invention are shown in  FIG. 6 . The tabs that are to be bent are identified in  FIGS. 3 and 4  with reference characters F and H.  
         [0051]     The TRAY should be trimmed so the long axis of the TRAY fits between the chair blocks that define the width of the rough opening. This can be done on the job-site using tools that will cut sheet metal. The locking tabs on the CLIPS that are positioned between the half-high blocks should be bent up to a vertical position and given a slight twist. The slight twist will create enough clearance for the front of the TRAY (reference character C) to slip between the face flange (reference character E) and the locking tab of the CLIP. The mounting and support tab (reference character H) of the CLIPS that are positioned between the half-high blocks should be bent up to a vertical position.  FIGS. 13 and 14  show CLIPS in the middle of the rough opening that have been bent in the prescribed manner. Next, the TRAY is placed in the rough opening with the front (reference character C) of the TRAY set against the inside of the face flanges (reference character E) between the face flange and the locking tab of the CLIPS that lie between the half-high blocks. The TRAY will be resting with its bottom surface (reference character B) on the upper edge of the mounting and support tab. The locking tabs are then untwisted to form a lock on the lower edge of the front of the TRAY. The relative position of these CLIPS and the TRAY can be seen in  FIGS. 22 and 23 . With the TRAY in this position it will also be resting on the mounting and locking flange (reference character G) of the CLIPS at the chair blocks. The positional relationship of the TRAY and the CLIPS in this location is shown in  FIGS. 18 and 19 . The locking tabs (reference character F) of the CLIPS at the chair block can now be bent over the top surface of the TRAY (reference character A). The positional relationship of a TRAY and a CLIP at this stage of installation is shown in  FIGS. 20 and 21 . Note that the locking tab has been bent out perpendicular to the chair block side. This can be seen in the finished installation in  FIG. 17 . A TRAY with cutouts so the CLIPS can be seen in the final stage of installation is shown in a rough opening in  FIGS. 14 and 15 . A completed assembly can also be seen in  FIGS. 24, 25 , and  26 .