Patent Publication Number: US-11391023-B2

Title: Concrete form for freestanding bath filler installation and method of use

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of and priority to U.S. Provisional Application No. 62/935,991, filed on Nov. 15, 2019, the entire disclosure of which is hereby incorporated by reference herein. 
    
    
     BACKGROUND 
     The present application relates generally to bath filler installation. More specifically, the present application relates to a concrete form for installing a freestanding bath filler. 
     Freestanding bath fillers may be mounted adjacent to a bathtub for filling the bathtub with water. They are typically mounted onto a floor and have a height sufficient to allow for positioning an outlet of the bath filler above a rim of the bathtub so that water may flow freely into the bathtub. Such freestanding bath fillers come in a wide variety of configurations and have varying feature sets. These bath fillers are connected to plumbing and are mounted in such a way as to stand next to the bathtub without being connected thereto. The present application is directed to improved systems and methods for installing such freestanding bath fillers. 
     In houses or dwellings without basements and crawl spaces, or in those that have poured concrete floors, freestanding bath fillers are typically installed into the concrete slab foundation. Installation of such a freestanding bath filler would typically require a complex process including excavating below grade, routing supply lines, and pouring concrete. Currently, installers are required to figure out how to install the bath fillers in concrete slabs with little guidance. Some freestanding bath fillers are secured to the floor, which creates a risk of damaging delicate tile. The concrete form disclosed in this application is designed to eliminate the guesswork of placing the bath filler mounting blocks, thus significantly simplifying the installation process. 
     The following description focuses primarily on concrete flooring installation, but it should be appreciated that the disclosed form can be formed on other floor surfaces in a bathing or shower environment (e.g., bathtubs, etc.) to provide guidance and aligning in various installation processes. Thus, it would be advantageous to provide an improved form that overcomes the foregoing challenges and provides a number of advantages, including having an aesthetically pleasing design and a structure that may be installed in a manner that advantageously helps to prevent cuts and scraped hands during the installation process. These and other advantageous features will become apparent to those reviewing the present disclosure. 
     SUMMARY 
     At least one embodiment relates to a concrete form for installing a bath filler. The concrete form includes a base having an exposed top surface, a perimeter wall extending along each side of the base and oriented perpendicular to the base, and a rim extending from a top edge of the perimeter wall outwardly from the exposed top surface. The concrete form includes at least one notch disposed along the rim, such that the at least one notch is configured to align with a desired location of the bath filler. The concrete form includes a drill template corresponding with the notches. The drill template includes a plurality of markers configured to indicate drill-hole placement. 
     Another embodiment relates to a freestanding bath filler system. The freestanding bath filler system includes a concrete form including a base having an exposed top surface, a perimeter wall extending along each side of the base and oriented perpendicular to the base, and a rim extending from a top edge of the perimeter wall outwardly from the exposed top surface. The concrete form includes at least one notch disposed along the rim, such that the at least one notch is configured to align with a desired location of the freestanding bath filler. The concrete form includes a drill template corresponding with the notches. The drill template includes a plurality of markers configured to indicate drill-hole placement. The freestanding bath filler system further includes a concrete pad formed underneath the concrete form, a mounting block configured to couple to the concrete pad through an opening corresponding to the drill template, and a flooring underlayment disposed on the rim of the concrete form. The mounting block is configured to support the freestanding bath filler and to receive a fluid supply line. 
     Another embodiment relates to a method of using a freestanding bath filler concrete form. The method includes placing a concrete form into a hole, routing at least one fluid supply line through an inlet of the concrete form, and aligning the concrete form, via at least one notch, with an orientation template configured for placement of at least the freestanding bath filler. The method further includes pouring concrete into the hole around the concrete form, drilling mounting holes for the freestanding bath filler mounting block through the concrete form using a drill template disposed on a base of the concrete form, removing the drill template from the concrete form, and coupling the mounting block to the concrete. 
     This summary is illustrative only and is not intended to be in any way limiting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which: 
         FIG. 1  is a schematic view of a concrete form, in accordance with an exemplary embodiment of the present application. 
         FIG. 2  is a perspective view of the concrete form shown in  FIG. 1 . 
         FIG. 3  is a perspective view of a notch of the concrete form shown in  FIG. 1 . 
         FIG. 4  is a perspective view of an installation step of the concrete form shown in 
         FIG. 1 . 
         FIG. 5  is a perspective view of an installation step of the concrete form shown in  FIG. 1 . 
         FIG. 6  is a perspective view of an installation step of the concrete form shown in  FIG. 1 . 
         FIG. 7  is a flow chart illustrating a method for using a concrete form for freestanding bath filler installation, in accordance with an exemplary embodiment of the present application. 
         FIG. 8  is a schematic view of an orientation template, in accordance with an exemplary embodiment of the present application. 
         FIG. 9  is a schematic view of a concrete form installed in a concrete slab, in accordance with an exemplary embodiment of the present application. 
         FIGS. 10-13  are perspective views of a notch of the concrete form, in accordance with another exemplary embodiment of the present application. 
         FIG. 14  is a perspective view of markers of the concrete form, in accordance with another exemplary embodiment of the present application. 
     
    
    
     DETAILED DESCRIPTION 
     Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting. 
     Referring generally to the figures, disclosed herein is a freestanding bath filler mounting block concrete form. The concrete form includes an upper flange to align with the existing poured concrete floor and a rim to support tile-backer or flooring underlayment to span the opening and reduce the likelihood of tile breakage or flooring damage. The form may contain pre-formed drill points along the outer perimeters so holes can be placed in numerous locations for routing the supply lines. 
     Referring to  FIG. 1 , a concrete form  100  is shown according to an exemplary embodiment. The concrete form  100  may be thermoformed plastic or injection molded plastic, for instance. The concrete form  100  includes a base  102 , which is generally rectangular, and a perimeter wall  104 . The base  102  may be rectangular or it may be any shape (e.g., triangular, circular, oblong, etc.) suitable for the installation space. The perimeter wall  104  extends perpendicular to the base  102  from the exposed surface of the base  102 , and extends along each side of the base  102 . Projecting perpendicular to the perimeter wall  104  and parallel to the base  102  may be a flange  108  and a rim  110 . The flange  108  and the rim  110  extend out from the top edge of the perimeter wall  104  and beyond the perimeter of the base  102  and are connected to each other in a step-like manner. The flange  108  and the rim  110  (e.g., a lip) are designed to align the concrete form  100  with the existing poured concrete and to support tile  107  or flooring underlayment  109 , respectively. In various other embodiments, only the rim  110  is provided. 
     Referring still to  FIG. 1 , drill points  106  (also shown in  FIG. 2 ) may be disposed on two sides of the perimeter wall  104 . There may be a plurality of drill points  106  along the sides to selectively drill holes through the concrete form  100  at the necessarily point to properly place and correspond with supply lines  111  (e.g., water supply lines). Drill points may be placed, for instance, every three inches along the desired sides of entry to ensure options for a variety of supply line placements. The drill points  106  position the inlets at the correct distance from the future poured concrete pad  113  by providing a clear route from the supply lines through the concrete form  100  prior to pouring the concrete. 
     As shown in  FIGS. 2-4 , notches  112  may be made on the flange  108  or the rim  110  to help further align the concrete form  100  with the bath placement. As shown in  FIG. 3 , the notches  112  may be defined by a cut out or by a ridge in the edge of the flange. However, the notches  112  may be any alternative feature configured to align the concrete form  100  with the future bath placement. For instance, as shown in  FIGS. 10-13 , the notches  112  could be molded or formed-in features such as raised bumps/protrusions, channels, or grooves. The notches  112  may also be formed by laser/engraving, cutting/milling grooves, marking with ink by pad printing, adding a label, etc. 
     The notches  112  may be used to indicate the center, for instance, of the concrete form  100  in order to allow accurate measurement and alignment with the pre-measured placements/scoring on the floor for the bath, for instance, prior to installation. However, the notches may be offset from the center as well if needed to better align with an off-center placement of the bath filler. The notches  112  allow the installer to visually align the orientation of the concrete form with the intended installation location. For example, an orientation template  200  is illustrated in  FIG. 8 . The orientation template  200  is configured according to specified dimensions d which are determined based on the particular bath and working space for each individual installation. A first chalk line  202  may be present on the concrete slab  203  to align the centerline of the filler, bath drain, and the length of the bath. A second chalk line  204  may be present on concrete slab  203 , running perpendicular to the first chalk line  202  and parallel to the width of the bath, thus indicating where the filler is intended to be installed (i.e., at the crossing point of the first and second chalk lines  202 ,  204 ). Further, a bath filler pocket  206  for placement of the bath filler, a drain pocket  208  for placement of the pipes, and a bath footprint  210  may be present to visualize the overall placement of the bath system. 
     As shown in  FIG. 9 , when the concrete is removed at the bath filler pocket  206  and the drain pocket  208 , a hole  212  is created. The notches  112  provide references to the true center of the concrete form  100  and are to be aligned with the first and second chalk lines  202 ,  204 , thus positioning the concrete form  100  where the bath filler is intended to be installed (i.e., where the cross-hair marking of the first and second chalk lines  202 ,  204  would be located had the hole  212  not been created). This ensures the markers  116  ( FIG. 2 ) are orientated correctly relative to the bath so the bath filler is aimed properly to the bath. Further, a board  214  may be placed over the top flange  108  and secured to the concrete form  100  with screws  216  to hold the concrete form  100  level with the plane of the remaining concrete slab  203 . The board  214  may also be secured to the concrete slab  203  to hold it in place while concrete is poured. The board  214  may be secured to the concrete form  100  adjacent the notches  112  so it can be aligned adjacent the second chalk line  204  on the concrete slab  203  as well. 
     The base  102  includes a drill template  114 . The drill template  114  may be circular, or a similar shape to a mounting block that will be used for the freestanding bath filler. The drill template  114  may have a plurality of markers  116  along its circumference. For example, when the concrete is cured, holes for the mounting block fasteners can be drilled directly through the concrete form  100 , as indicated by markers  116  on the drill template  114 , thus ensuring proper placement of the mounting block. The drill template  114  may be centered along the base  102  or may be offset from the center in any direction. The drill template  114  is perforated and can be removed (as shown in  FIG. 4 ). Removing the drill template  114  to expose an opening  118  ensures the most stable connection between the mounting block and the concrete. 
     Alternatively, if the form is injection molded rather than thermoformed, then it would be advantageous to mold in long bosses into the drill template  114  to form integral “drill bushings” (e.g., the markers  116 ), as shown in  FIG. 14 . The markers  116  as bosses will help to ensure the holes for the mounting block are perpendicular to the surface being drilled. The markers  116  may also aid in the removal of the drill template  114  from the concrete form  100 . Not shown but optional are any connecting ribs or structures meant to keep these bosses perpendicular to the surface. The integral drill bushing, or the markers  116 , may be about 7/16″ diameter by about ½″ tall, or any other height and diameter. The integral drill bushing or markers  116  may also include an optional chamfered or rounded entrance and/or exit. 
     Referring to  FIGS. 5-6 , a mounting block  120  can then be placed within the concrete form  100  and secured to the concrete pad  113 , such as through the opening  118  in the base  102  of the concrete form  100 . The mounting block  120  supports a free standing bath filler and receives the hot and cold water supplies, which route through the holes corresponding to the drill points  106  and into openings in the mounting block  120  to the bath filler. The tile-backer or flooring underlayment  109  is then placed on the rim  110  of the concrete form  100  and installation of the concrete form  100  is complete. A freestanding bath filler  122  (as shown in  FIG. 1 ) may then be connected to the mounting block  120 . The freestanding bath filler  122  will extend above the tile  107  and be further configured to route water from the supply lines  111  to fill a bathtub, for instance. 
     Referring to  FIG. 7 , a method  700  for using a freestanding bath filler concrete form is shown according to an exemplary embodiment. At step  702 , the installation location is marked on the concrete slab. Chalk lines can be snapped to indicate the X, Y locations of the bath filler&#39;s center. At step  704 , the concrete slab is cut and removed for plumbing placement, such as the supply lines. Cutting the concrete may be done using a saw, hammer drill, sledgehammer, jack hammer, chisel and hammer, etc. For a new construction site, if the working space is not poured with concrete (e.g., a site-built 2-by lumber or a similar form which “reserves” the space), significant labor can be eliminated. The supply lines are placed below grade, projecting the floor surface where desired. Plumbing inspection may occur here at this point. At step  706 , the installer drills holes in the side of the concrete form where the supply lines are to be placed. Optionally, at step  707 , a board is secured to the form in-line with one set of notches on the concrete form. At step  708  and  710 , the concrete form is placed into the hole and supply lines are routed through the inlet holes previously drilled. Specifically, at step  708 , the concrete form is aligned with the orientation template for bath placement via the notches in the center of the four sides. If the board was used at step  707 , the board is also placed and aligned with the notches. Voids may be filled with plumber&#39;s putty or a suitable construction material. At step  712 , the new concrete is poured and cured. If the board was used to hold the concrete form in place, it is now removed. At step  714 , the installer drills mounting holes for the bath filler mounting block through the form using the drill template on the base. At step  716 , the installer scores the concrete form with a utility knife and removes the drill template from the concrete form. At step  718 , the installer secures the mounting block to the concrete pad and makes water supply connections. At step  720 , the installer places fabricated underlayment/tile-backer onto the rim of the concrete form. Thus, the flooring and bath filler mounting block are installed. 
     The present disclosure describes a concrete form that can, advantageously, provide guidance and alignment for freestanding bath fillers. Benefits of the concrete form and methods described herein include, for example, a template to better position the bath filler mount and water lines prior to thus creating a “knuckle saver” solution, allowing installers to increase efficiently, accuracy and ease during the installation process. 
     As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims. 
     References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. 
     The construction and arrangement of the elements as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. 
     Additionally, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Rather, use of the word “exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims. 
     Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. For example, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also, for example, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims. 
     While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination. 
     Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In some cases, the actions recited herein can be performed in a different order and still achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various components in the embodiments described above should not be understood as requiring such separation in all embodiments.