Tool and Method for Forming Shower Base Elements

Abstract

A tool and a method for creating a base element for a shower installation are disclosed. Specifically, the tool relates to a multi-level, rotary mounted form arm and an edge support for forming mortar into a properly sloped shower base.

Claims

1. A system for forming and constructing a shower pan comprising: a) a rotary mounted forming tool comprising a generally perpendicular vertical shaft with radially affixed length-adjustable form arm wherein said radially affixed length-adjustable form arm is affixed at one end to said vertical shaft; b) an adjustment screw end support affixed at the outer end of said radially affixed length-adjustable form arm; and c) a height-adjustable support structure with affixed stabilizing elements wherein said stabilizing elements are transversely inserted through slots formed in said height-adjustable support structure.

2. A system for forming and constructing a shower pan of claim 1 wherein the generally perpendicular vertical shaft is anchored at the drain of the shower.

3. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of wood.

4. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of aluminum.

5. A system for forming and constructing a shower pan of claim 1 wherein the radially affixed length-adjustable form arm is constructed of fiberglass.

6. A system for forming and constructing a shower pan of claim 1 wherein: a) the length-adjustable form arm is supported at its terminal end by an adjustment screw end support to form a pre-shower slope; and b) the length-adjustable form arm is supported at its terminal end by a height-adjustable support structure with affixed stabilizing elements to form a shower pan.

7. A method of using a system for forming and constructing a shower pan of claim 6 to form a pre-shower slope and a shower pan comprising the following steps: a) affixing a rotary mounted form tool to a drain flange wherein said rotary mounted form tool is bolted to said drain flange and said drain flange is installed in a shower area; b) affixing a radially affixed length-adjustable form arm to said rotary mounted form tool wherein said radially affixed length-adjustable form arm is located at a user selectable height above said rotary mounted form tool and the adjustment screw end support is adjusted such that the grade of the radially affixed length-adjustable form arm slopes towards the drain flange; c) pouring mortar into the shower area; d) rotating the radially affixed length-adjustable form arm to form a pre-shower slope; e) allowing time for the concrete pre-shower slope to cure; f) placing a plastic drain liner over a cured pre-shower slope; g) re-affixing the rotary mounted form tool to the drain riser wherein said rotary mounted form tool is screwed to said drain riser and said drain riser is installed in a shower area; h) re-affixing the radially affixed length-adjustable form arm to said rotary mounted form tool wherein said radially affixed length-adjustable form arm is located at a user selectable height above said rotary mounted form tool; i) installing a height-adjustable support structure with affixed stabilizing elements around the outer perimeter of the shower area such that the radially distant end of the length-adjustable form arm is supported on said height-adjustable support structure and the grade of the radially affixed length-adjustable form arm slopes towards the drain flange; j) pouring mortar into the shower area; and k) rotating the radially affixed length-adjustable form arm to form the mortar into a shower pan.

8. A system for forming and constructing a shower pan comprising: a) a rotary mounted forming tool comprising a generally perpendicular vertical shaft with radially affixed length-adjustable form arm wherein said radially affixed length-adjustable form arm is affixed at one end to said vertical shaft, and b) a laser pointer horizontally mounted on the distal end of the radially affixed length-adjustable form arm.

9. A system for forming and constructing a shower pan of claim 8 wherein the generally perpendicular vertical shaft is anchored at the drain of the shower.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1a is a diagram showing the rotary mounted form tool and length-adjustable form arm.

[0016] FIG. 1b is close-up diagram showing the rotary mounted form tool.

[0017] FIG. 2 is an elevation view showing the rotary mounted form tool and length-adjustable form arm being used to mold a pre-shower slope.

[0018] FIG. 3 is an elevation view showing the rotary mounted form tool and length-adjustable form arm being used to mold a shower pan area.

[0019] FIG. 4 is a plan view showing the rotary mounted form tool and length-adjustable form arm in typical relation to the height-adjustable support structure with stabilizing elements.

[0020] FIG. 5 is an elevation view showing the height-adjustable support structure slotted to support stabilizing elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0021] Referring now to FIGS. 1 through 5 the exemplary embodiment of the present invention comprises two components: 1) A rotary mounted forming tool 100; and, 2) A height-adjustable support structure 140 capable of being aligned to support the rotating end of rotary mounted forming tool 100.

[0022] Rotary mounted forming tool 100 is comprised of central mount 101 capable of being affixed to drain flange 110 and drain riser 131 of a shower stall. Central mount 101 has vertical shaft 103 affixed to it via ball joint 102. Central mount 101 may be affixed directly to drain flange 110 and subsequently affixed to drain riser 131. Central mount 101 has two sets of holes: 1) A first set 101a driven such that central mount 101 may be affixed by bolts to drain flange 110; and, 2) A second set 101b driven such that central mount 101 may be affixed by screws to drain riser 131.

[0023] Horizontally attached to vertical shaft 103 of central mount 101 is length-adjustable form arm 100a. Vertical shaft 103 is equipped with visual markings showing the height of length-adjustable form arm 100a above central mount 101. Vertical shaft 103 is affixed to central mount 101 by means of ball joint 102. Length-adjustable form arm 100a is comprised of near arm 105 and distal arm 106. Length-adjustable form arm 100a is attached to vertical shaft 103 at central pivot hole 104. Length-adjustable form arm 100a is secured to vertical shaft 103 by means of adjustment screw 105a. It will be obvious to one having skill in the art that adjustment screw 105a is not the only means of affixing length-adjustable form arm 100a to vertical shaft 103. Pins or clips may also be used in lieu of adjustment screw 105a. Near arm 105 and distal arm 106 are adjustably affixed together by screws 107a. Screws 107a are inserted through holes and adjustable length slot 107b. It will be obvious to one having skill in the art that the holes may be drilled in either near arm 105 or distal arm 106. Similarly, adjustable length slot 107b is formed in the opposing distal arm 106 or near arm 105. Adjustment screw end support 108 may be vertically screwed through the terminal end of distal arm 106 and is capable of supporting the terminal end of distal arm 106 and attached near arm 105 by means of its affixed terminal pad 109.

[0024] Referring specifically to FIG. 2, in an alternative embodiment of the present invention is disclosed. In this embodiment, laser 111 generating laser point 111a may be affixed to the distal end of distal arm 106. Laser point 111a is projected onto the side of the shower enclosure.

[0025] Referring now to FIGS. 4 and 5, height-adjustable support structure 140 is a plastic strip capable of being placed on the ground around the outer perimeter of the shower area. Cut or molded into height-adjustable support structure 140 at regular distances along its length are repeating series of vertical slots 142. Each slot in each series of repeating series of vertical slots 142 are different lengths. For example, the preferred embodiment of the present invention has slots that are , , , and long and each slot is placed apart. Placed crosswise into these slots at regular distances from one another are stabilizing elements 141. Stabilizing elements 141 are used to adjust the height of height-adjustable support structure 140 at various points on its outer circumference when it is installed.

[0026] Referring again to FIGS. 1 through 5, the exemplary embodiment of the present invention is used in the following manner: First, central mount 101 of rotary mounted forming tool 100 is attached to roughed in drain flange 110. Next, central pivot hole 104 of length-adjustable form arm 100a is inserted on vertical shaft 103. Next, fixing adjustment screw 105a and adjustment screw end support 108 are adjusted so that the grade formed by length-adjustable form arm 100a is within code for a pre-shower slope. The user tightens fixing adjustment screw 105a. Next, the user mixes mortar and pours it into the shower pan area. Next, the user rotates length-adjustable form arm 100a around vertical shaft 103 to mold a pre-shower slope. Next the user removes rotary mounted forming tool 100 and length-adjustable form arm 100a from roughed in drain flange 110. Next, the user lets the pre-shower slope dry. Next, the user positions shower liner 121 over cured pre-shower slope 120. Next, the user secures shower liner 121 using shower liner lock plate 130 over drain flange 110. Next, the user positions drain riser 131 in shower liner lock plate 130 at the proper height. Next, the user removes adjustment screw end support 108 from the distal end of length-adjustable form arm 100a. Next, the user screws rotary mounted forming tool 100 to drain riser 131. Next, the user places height-adjustable support structure 140 around the peripheral extent of the shower pan area. Next, the user inserts stabilizing elements 141 through vertical slots 142 at suitable points along the length of height-adjustable support structure 140 to adjust the height of height-adjustable support structure 140 such that the grade formed by length-adjustable form arm 100a as it rests with its distal end on top of height-adjustable support structure 140 that is set in compliance with the proper code specified for the final grade of the shower pan. Next, the user mixes mortar for shower pan 150 and pours it into the shower pan area. Next, the user rotationally flexes length-adjustable form arm 100a on top of and around height-adjustable support structure 140 to mold a shower pan. Next, the user removes rotary mounted forming tool 100 and length-adjustable form arm 100a from drain riser 131. Next, the user lets the shower pan dry. Finally, the tile installer installs tile over the cured shower pan 150.

[0027] Referring now specifically to FIG. 2, an alternative embodiment of the present invention is used in an alternative manner: Specifically, laser point 111a generated by laser 111 is aligned with level lines drawn on the sides and end of the shower stall. This is done both to form both pre-shower slope 120 and to form the shower pan. Height-adjustable support structure 140 is not required using this embodiment.

[0028] While the present invention has been described in what are thought to be the most useful and practical embodiments, it will be readily apparent to those having skill in the art that other variations may be readily conceived and created. Accordingly, these and all such other readily conceived and created variations are implicitly included in the spirit and scope of the present disclosure.