A PROCEDURE FOR MANUFACTURING A DEVICE FOR CASTING A SLOPE OF A FLOOR, A DEVICE AND A METHOD FOR CASTING A SLOPE

Description

Technical Field

[0001] The present invention relates to a procedure for manufacturing a device intended to be used for casting a slope of a floor with a correct inclination toward a floor drain.

[0002] Also, the present invention relates to a device, intended to be used for casting a slope of a floor toward a floor drain, comprising a bottom surface which corresponds to the inclination of the slope and a part that is arranged at said bottom surface for arrangement to the floor drain.

[0003] Also, the invention relates to a method for casting a slope of a floor toward a floor drain by using a device manufactured according to the procedure.

Background of the invention

[0004] In different types of rooms or spaces in an ordinary house or in other buildings, such as garages, sport halls, swimming arenas, and industrial facilities or plants, there is a need for one or more floor drains arranged into the floor for discharging water. For example, floor drains are necessary in shower rooms, bathrooms, lavatories, laundry rooms, garages, or in floors of balconies and terraces, where waste water, excess water or rain water can be pooled and then must be discharged. The floor of such a space or an area is designed to allow water to flow towards the floor drain or waste water outlet.

[0005] In most cases, said floors are constructed by firstly produce an under floor made of cement, concrete or similar material. A floor drain is then arranged in the concrete floor. Thereafter, a slope toward the floor drain is constructed by use of solid putty or solid spackling paste to form an inclined part of the floor, which is manually made by hand. An upper layer is then applied by supplying floating putty or floating spackling paste on top of the inclined part and on the rest of the floor for adapting the slope in alignment with the rest of the floor and for providing a smooth surface of the floor. Finally, a top layer may be provided by titles, hard-burned bricks or clinkers with joint filling material between these.

[0006] The difficulty in obtaining a symmetric slope toward and around the floor drain in accordance to construction standards is a well-known problem, since the slope often is manually made and the result depends on the skill of the person performing the work.

[0007] Experienced craftsmen can produce such floors so that the floor drops evenly toward the floor drain according to determined construction standards, which for example is a requirement for a shower area. It is a well-known fact that a skilled person within the art cannot reproduce the same slope at every occasion since it is made by hand, and also that this is a laborious and time consuming moment despite long experience.

[0008] A less skilled person or a trainee needs more time, and problems can arise to reach construction standards.

[0009] Floors that are inclined too steeply are uncomfortable and are a slipping risk for a user of for example a shower, and a floor that are not inclined enough results in a poor drain. A slope that is unsymmetrical around the floor drain results in pooling of water in corners of the wet area or tends to pool water in other undesired areas. This can lead to cracks in the joint filling material and to mildew arising into the cracks, or even worse; overflow in adjacent rooms.

[0010] SE 470216 B describes a method of casting a slope toward a floor drain wherein a device is provided that has a lower surface that corresponds to the desired slope toward the floor drain. The floor or at least a part of the floor is casted around and beneath the device. The device for casting such a slope comprises a form with a lower surface corresponding to the desired slope toward the floor drain and a holder for the form that is attachable in relation to the floor drain. The form has a hole arranged through the lower surface which is in engagement with means of the holder at attachment of the holder to the floor drain.

[0011] The Swedish patent application SE1100231-8 describes a cone shaped casting form for casting a sloped floor toward a floor drain. The casting form with a tip is placed over a floor drain to which the tip is attached. When floating putty or cement has been supplied and has dried, the material under the casting form obtains the same angle as the casting form.

[0012] US6568140 shows a plate with an inclined bottom surface. The plate is used as a form to obtain a drop of the slope toward a floor drain when casting cement floors. The bottom side of the plate provides a fan shaped gradient into the cement under the form toward the floor drain.

[0013] The existing forms on the market for casting a slope toward a floor drain have limitations since existing models only show a weak stability and hence have limited usability.

[0014] There is a strong demand within the building trade to find an effective and time saving way for making a slope toward a floor drain by means of a device and to repetitively reach approved standard, which also is ergonomic and simple to apply for a professional worker within this field.

Summary of the invention

[0015] An object of the present invention is to mitigate or eliminate one or more deficiencies and disadvantages of the prior art, and to provide a procedure for manufacturing a device intended to be used for casting a slope with correct inclination toward a floor drain according to claim 1.

[0016] A more specific object of the present invention is to provide a procedure for manufacturing a device intended to be used for casting a slope with correct inclination toward a floor drain, where the device comprises a bottom surface which corresponds to the inclination of the slope and a part that is arranged at said bottom surface for connection to the floor drain.

[0017] The procedure comprises to provide an element having a first and a second sheet of metal foil, which are arranged in parallel to each other, and a core of polymeric material between the first and second sheet. A through circular hole is made into the element, and is arranged at the center of the element. Several grooves are made into the first sheet, which are arranged along their lengths between an outer circumference of the element and the circular hole to allow the polymeric material of the core to flow out into the groves. The grooves are symmetrical arranged, and has a width of 1 to 10 mm, preferably 2 to 6 mm. The number of grooves may vary, for example 4 to 16, and according to a preferred embodiment the number is 8.

[0018] Heat is supplied to the element, for example by radiation such as infrared (IR) radiation, induction, convection or conduction, and also hybrid solutions can exist. A pressure force is applied to the first sheet of metal foil for forming the sheets of metal foil so that the bottom surface of the element corresponds to an inclination that provides a correct slope toward the floor drain, and simultaneously for bending the edges of the circular hole downwards forming a tubular part intended to be connected to the floor drain. During the form pressing, the polymeric material is allowed to flow out into the grooves of the first sheet in a zone adjacent to the tubular part close to the circular hole. The preheating temperature on the sheet is adapted so that the zones which require the largest change in form will get a higher temperature. When using IR-radiation, this is made by applying a dark layer, such as dark color or a dark foil layer, to said zone surrounding the circular hole, before supplying heat, for increasing the ability of the element to absorb heat in this zone, when heat is supplied, and in such way increase the formability of the element.

[0019] The pressure force is applied by means of a pressing tool. The metal foils serve as cooling flanges during the cooling of the device, which will reduce the time for production of the device.

[0020] In a second aspect the invention relates to a device, which is manufactured according to the procedure and which is intended to be used at casting a slope of o floor toward a floor drain, wherein the device comprises a bottom surface that corresponds to the inclination of the slope and a part that is arranged at said bottom surface intended for connection to the floor drain.

[0021] In a third aspect the invention relates to a method for casting a slope of a floor toward a floor drain by using a device manufactured according to the procedure. The method comprises to provide the device with a bottom surface, which corresponds to the inclination of the slope, and a tubular part for connecting to the floor drain, and then to connect the device to the floor drain. Further, levelling-screws are provided, which are arranged in the grooves at the outer circumference of the device and which are going through the polymeric core and said second metal foil, and by which the device is horizontally aligned in relation to the floor. By means of the levelling-screws the device is aligned in relation to the floor to secure that the bottom surface of the device will take and maintain a correct inclination. Floating putty is supplied so that the interspace between the device and the floor is filled in, finally the levelling-screws are cut off and the device is removed when the floating putty has solidified.

[0022] Further objects, features and advantages of the present invention will appear from the following detailed description, the attached drawings and the dependent claims.

Brief description of the drawings

[0023] In order to explain the invention, embodiments of the invention will be described below with reference to the drawings, in which:

Fig 1 shows schematically an element of a device intended to be used for casting a slope toward a floor drain,

Fig 2 shows schematically the element of the device in Fig 1, which has been provided with grooves in a first sheet and a trough hole,

Fig 3 shows schematically the element in Fig 1 according to an alternative embodiment,

Fig 4 shows schematically the device arranged to the floor drain at casting the slope toward the floor drain, and

Fig 5 shows schematically the finished slope toward the floor drain.

[0024] Same reference numerals have been used to indicate the same parts in the figures to increase the readability of the description and for the sake of clarity.

Description of embodiments of the invention

[0025] A procedure for manufacturing a device 40 intended to be used for casting a slope with a correct inclination toward a floor drain 41 according to the invention will be described below with reference to the drawings.

[0026] The device comprising a bottom surface 42 that corresponds to the inclination of the slope and a part 44, which is arranged at said bottom surface for connection to the floor drain and which is produced according to the procedure, will also be described.

[0027] A method for casting a slope toward a floor drain by means of the device 40 that is manufactured by the procedure will then be described.

[0028] Elements with a good flexural rigidity and a good bending strength, while simultaneously other criteria such as low weight and low price must be satisfied, are available as prefabricated elements for use within different types of construction. One example is sandwich structures comprising sheet elements with different properties. Since such an element also must present properties as being formable by means of different technologies where the final product must have a specific shape with maintained flexural rigidity, a deeper material knowledge is required for choosing material and process technology to obtain the final product with desired properties at casting.

[0029] A device 40 that is intended to be used at casting a slope of a floor 43 must have a specific inclination of a bottom surface 42 which corresponds to the slope of the floor. By using a prefabricated element 10 comprising two sheets of metal foil 11, 12 that are arranged in parallel with a polymeric core 13 arranged between said sheets, the device can be manufactured according to the invention.

[0030] Fig 1 shows an element 10 that will be used as a blank for producing the device. The element comprises a first sheet 11 and a second sheet 12, which both are made of metal foil and are arranged in parallel with each other. Further, the element comprises a polymeric core 13 that is arranged between said first and second metal foil. The sheets are for example made of aluminum, or an alloy of aluminum and another metal. The element has a thickness of about 3-5 mm as a prefabricated blank, according to a first embodiment the thickness is 4 mm, which means that it is light and simultaneously has stiffness. The element is square according to the first embodiment, and has a width and a length of 1000-1500 mm, respectively, preferably 1200 mm. This size of the element ensures that a slope toward a floor drain with a correct inclination can be produced without later adjustment of the slope, since the element is able to cover the entire area surrounding the drain.

[0031] The procedure for manufacture of the device is initiated by providing an element 10 according to Fig 1. Then, a through hole 20 is made in the element by means of a cutting tool or a boring tool. The hole is arranged in the center of the element according to a first embodiment, and has a diameter of 10-16 mm, preferably 14 mm.

[0032] Thereafter, grooves 21 are made in the first sheet 11 of the element. The grooves are arranged between the outer circumference of the element and the circular hole 20. Said grooves are going through the sheet according to a first embodiment, and are symmetrically arranged between the outer circumference of the element and the circular hole. The grooves have a width of 1-10 mm, preferably 4 mm. The grooves are arranged for increasing the formability of the element during heating, which will be explained in detail below. According to an alternative embodiment, the grooves can be made through only in some parts of the grooves, while being not through in the remaining parts.

[0033] Fig 2 shows a device with four grooves which are through, and which are arranged between the middle of the sides of the element and the circular hole.

[0034] Fig 3 shows a device with eight grooves which are through, and which are arranged between the middle of the sides of the element and the circular hole, and along the diagonals and the hole, showing a preferred embodiment. According to an alternative embodiment, the element can comprise 12 or 16 grooves symmetrically distributed between the outer circumference of the element and the circular hole.

[0035] Further, the element comprises a zone 22, which surrounds the circular hole and which is coated by a dark layer for increasing the ability to absorb heat in the zone in order to increase the formability of the element in this zone, as described below. For example, the zone can be coated by a layer of black color or a black foil layer.

[0036] The next step at the manufacturing of the device is to heat up the element 10 by radiation, conduction, convection, induction, or by combinations of these or by other means. For example, IR-lamps are used for the heating, which will give a desired temperature difference between the zone 22 surrounding the circular hole 20 and the remaining part of the element to increase the freedom to form said zone. The temperature of said zone having the dark layer is about 30 % higher after heating than the rest of the surface of the element.

[0037] Thereafter, the element is placed in a pressing tool (not shown), and a pressing force is applied to the first sheet 11 of metal foil for forming the sheets so that the bottom surface of the element obtains an inclination which corresponds to a correct slope toward the floor drain. Simultaneously, by effect from the pressing force, the edges of the circular hole are bent downwards forming a tubular part 44, which is intended to be connected to the floor drain 41, and the polymeric material flows out into the grooves of the first sheet in the zone 22 around the circular hole 20 and at the passage to the tubular part 44 close to the circular hole.

[0038] When the element 10 has been heated, a moderate pressing force can be used for forming the slope, which corresponds to the bottom surface of the device 40. Due to the grooves 21 of the first sheet 11, the polymeric material is allowed to flow out into said grooves. This provides a large freedom to form the element, especially in the zone 22 around the circular hole 20, which also contributes to keep the pressing force low and to reduce enclosed tensions of the element.

[0039] Finally, the produced device is cooled down while being in the pressing tool. During this step the foil sheets 11, 12 function as cooling flanges, which allow a short cooling cycle. The device 40 according to the procedure is now ready to be used for casting a slope toward a floor drain.

[0040] Fig 4 illustrates a method for casting a slope of a floor 43 toward a floor drain 41 by use of the device 40 produced according to the above described procedure.

[0041] The method comprises to provide the device 40 having a bottom surface 42, which corresponds to the inclination of the slope, and a tubular part 44 that is arranged at said bottom surface which is intended for connection with the floor drain. The device is connected to the floor drain by said tubular part. Levelling-screws 45 are provided and are arranged into the grooves at the outer circumference of the device, and through the polymer core and said second metal foil. Thereafter, the device 40 is horizontally aligned in relation to the floor 43, and the device is adjusted to the floor by means of the levelling-screws 45 to secure that its bottom surface 42 has and maintains a correct inclination toward the drain. The levelling-screws also provide a possibility to adapt the device to different floor materials to obtain a desired inclination toward the floor drain. Thereafter, floating putty 46 is supplied beneath the device so that the interspace between the bottom surface and the floor is filled. Finally, the levelling-screws are cut off and the device is removed when the floating putty has solidified.

[0042] Fig 5 shows that the inclination of the bottom surface of the device in relation to the floor is determined by a rate between a value A and a value B, where A is defined as the distance between the center of the floor drain to an outer point at the bottom surface of the device, and B is defined as the perpendicular distance between said outer point and the floor. For example, an ordinary Swedish construction standard is an inclination of 1:50, which means that when A is 1000 mm the value of B should be 20 mm.

[0043] An advantage of the invention is that the size of the device ensures that a slope with correct inclination toward a floor drain can be produced without later manually adjustment of the slope, since the device covers the whole area around a drain and which shall include the slope.

[0044] A further advantage is that the device according to the invention provides a large flexibility at casting the slope toward a floor drain when these are not symmetrically arranged in a sanitary room or the like. It is easy to cut into the device for adapting it to drains which are placed close to a wall, and simultaneously maintain the stiffness of the device so that the inclination of the bottom surface is unchanged.

[0045] The benefits gained by the device described will increase the possibility to produce slopes according to approved standards in a repetitively and effective way, despite differences in the skills of the users of the device, which is a highly requested demand from both the construction business and the insurance companies for avoiding expensive complaints and damages.

[0046] The description above shall be considered as an exemplification of the principles of the invention and are not intended to limit the invention to the specific embodiments as illustrated. Other embodiments than the ones described can exist within the scope of protection, for example an alternative embodiment of the device can be produced by an element having another shape, such as rectangular, circular or polygonal.

Claims

1. A procedure for manufacturing a device (40) comprising a bottom surface (42), a through circular hole (20) and a tubular part (44) for connection to a floor drain, where the device is intended to be used for casting a slope with correct inclination toward the floor drain (41), characterized by the steps of:

- providing an element (10) comprising a first (11) and a second (12) sheet of metal foil, which are arranged in parallel to each other, and a core (13) of a polymeric material that is arranged between said first (11) and second (12) sheet;

- taking out the through circular hole (20) of the element (10);

- making several grooves (21) in said first sheet (11), which are arranged along their lengths between the outer circumference of the element (10) and the circular hole (20) for allowing the polymeric material to flow out into the grooves (21);

- supplying heat to the element (10); and

- applying a pressing force to the first sheet (11) of metal foil for forming the sheets (11, 12) of metal foil so that the bottom surface (42) of the element (10) corresponds to an inclination that provides a correct slope toward the floor drain (41) and, simultaneously, for bending the edge of the circular hole to form the tubular part (44) intended to be connected to the floor drain (41), wherein the polymeric material flows out into the grooves (21) of the first sheet in a zone (22) at the passage to the tubular part (44) close to the circular hole (10).

2. The procedure according to claim 1, further comprises applying a dark coating, such as black color or a dark foil layer, to said zone (22) surrounding the circular hole (20) of the element (10) before heat is supplied for increasing the ability to absorb heat in this zone (22) at supplying of heat and in such way increase its formability.

3. The procedure according to claim 1 and 2, wherein heat is supplied by radiation, such as IR-radiation, induction, convection or conduction.

4. The procedure according to claim 1, wherein the circular hole (20) is arranged in the center of the element.

5. The procedure according to claim 1, wherein 4 to 16 grooves (21) are arranged in the first sheet (11).

6. The procedure according to claim 1 and 5, wherein the grooves (21) are arranged symmetrically between the outer circumference of the element (10) and the circular hole (20).

7. The procedure according to claim 1, 5 and 6, wherein the grooves (21) are made with a width of 1 to 10 mm, preferably 2 to 6 mm.

8. The procedure according to claim 1, and 5-7, wherein the grooves (21) are made through along their lengths.

9. The procedure according to claim 1 and 5-7, wherein the groves (21) are made through in one or several parts of their lengths, and are made not through in the remaining parts.

10. The procedure according to claim 1, wherein the pressing force is applied by means of a pressing tool.

11. The procedure according to claim 10, wherein the metal foils (11, 12) serve as cooling flanges for cooling the device (40).

12. A device (40) intended to be used for casting a correct slope toward a floor drain (41) comprising a bottom surface (42), which corresponds to the inclination of the slope, and a through circular hole (20) and a part (44) for connection to the floor drain, characterized by,

- comprising an element (10) with a first (11) and a second (12) sheet of metal foil, which are arranged in parallel to each other, and a core (13) of a polymeric material that is arranged between said first and second sheet, wherein said first sheet of metal foil has several grooves (21) which are arranged along their lengths between the outer circumference of the device (40) and the circular hole (20) to allow the polymeric material of the core to flow out in the grooves (21) at supply of heat to the element (10), and

wherein the sheets of metal foil (11,12) of the element (10) are formed by applying a pressing force on the first sheet (11) after heat supply for forming the inclined shape of the bottom surface (42) of the device (40) and simultaneously the edges of the hole (20) are bent downwards forming a tubular part (44) intended for connection to the floor drain (41), wherein the polymeric material has flown out into the grooves (21) of the first sheet (11) in a zone (22) at the passage to the tubular part (44) close to the circular hole (20).

13. The device (40) according to claim 12, characterized in that the device (40) has a length and a width of 1000-1500 mm, preferably 1100-1200 mm, which ensures that a slope toward a floor drain (41) with a correct inclination can be manufactured without later adjustment of the slope.

14. A method for casting a slope to a floor toward a floor drain (41) by use of the device (40) according to claim 12 and 13, comprising the steps of:

- providing the device (40) comprising a bottom surface (42) which correspond to the inclination of the slope and a tubular part (44) that is arranged at said bottom surface (42) for connection to the floor drain (41);

- connecting the device (40) to the floor drain (41) by said tubular part (44);

- providing levelling-screws (45) which are arranged in said grooves (21) at the outer circumference of the element (10) and which are going through the polymeric core and said second metal foil (12);

- aligning the device (40) horizontally in relation to the floor and adjusting the device (40) in relation to the floor by means of the levelling-screws to ensure that the bottom surface (42) of the device (40) has and maintains a correct inclination;

- supplying floating putty beneath the device (40) so that the interspace (46) between the device (40) and the floor is filled; and

- cutting off the levelling-screws and removing the device (40) when the floating putty has solidified.

15. The method according to claim 14, wherein the slope of the bottom surface (42) of the device (40) in relation to the floor (43) is determined by the rate of a first value A and a second value B, wherein A is defined as the distance between the center of the floor drain (41) to an outer point at the bottom surface (42) of the device (40), and B is defined as the perpendicular distance between said outer point and the floor.

Ansprüche

1. Verfahren zur Herstellung einer Vorrichtung (40), die eine Bodenfläche (42), ein kreisförmiges Durchgangsloch (20) und einem rohrförmigen Teil (44) zum Anschluss an einen Bodenablauf umfasst, wobei die Vorrichtung zum Gießen eines Gefälles mit korrekter Neigung in Richtung des Bodenablaufs (41) verwendet werden soll, gekennzeichnet durch die Schritte des:

- Bereitstellens eines Elements (10), das eine erste (11) und eine zweite (12) Platte aus Metallfolie, die parallel zueinander angeordnet sind, und einen Kern (13) aus einem Polymermaterial umfasst, der zwischen der ersten (11) und der zweiten (12) Platte angeordnet ist;

- Entfernens des kreisförmigen Durchgangslochs (20) aus dem Element (10);

- Erzeugens mehrerer Rillen (21) in der ersten Platte (11), die entlang ihrer Länge zwischen dem Außenumfang des Elements (10) und dem kreisförmigen Loch (20) angeordnet sind, damit das Polymermaterial in die Rillen (21) hinein ausfließen kann;

- Zuführens von Wärme zu dem Element (10); und

- Aufbringens einer Andruckkraft auf die erste Platte aus Metallfolie (11) zum Bilden der Platten (11, 12) aus Metallfolie, so dass die Bodenfläche (42) des Elements (10) einer Neigung entspricht, die ein korrektes Gefälle in Richtung des Bodenabflusses (41) bereitstellt, und gleichzeitig zum Biegen des Randes des kreisförmigen Lochs, um den rohrförmigen Teil (44) zu bilden, der an den Bodenabfluss (41) angeschlossen werden soll, wobei das Polymermaterial in einer Zone (22) am Durchgang zum rohrförmigen Teil (44) nahe dem kreisförmigen Loch (10) in die Rillen (21) der ersten Platte ausfließt.

2. Verfahren nach Anspruch 1, weiter umfasst ein Aufbringen einer dunklen Beschichtung, wie z.B. einer schwarzen Farbe oder einer dunklen Folienschicht, auf die das kreisförmige Loch (20) des Elements (10) umgebende Zone (22), bevor Wärme zugeführt wird, um die Fähigkeit zur Wärmeaufnahme in dieser Zone (22) bei der Zufuhr von Wärme zu erhöhen und auf diese Weise ihre Formbarkeit zu erhöhen.

3. Verfahren nach Anspruch 1 und 2, wobei Wärme durch Strahlung, wie z.B. IR-Strahlung, Induktion, Konvektion oder Konduktion, zugeführt wird.

4. Verfahren nach Anspruch 1, wobei das kreisförmige Loch (20) in der Mitte des Elements angeordnet ist.

5. Verfahren nach Anspruch 1, wobei 4 bis 16 Rillen (21) in der ersten Platte (11) angeordnet werden.

6. Verfahren nach Anspruch 1 und 5, wobei die Rillen (21) symmetrisch zwischen dem Außenumfang des Elements (10) und dem kreisförmigen Loch (20) angeordnet sind.

7. Verfahren nach Anspruch 1, 5 und 6, wobei die Rillen (21) mit einer Breite von 1 bis 10 mm, bevorzugt 2 bis 6 mm, erzeugt werden.

8. Verfahren nach Anspruch 1 und 5-7, wobei die Rillen (21) entlang ihrer jeweiligen Länge durchgezogen werden.

9. Verfahren nach Anspruch 1 und 5-7, wobei die Rillen (21) in einem oder mehreren Teilen ihrer jeweiligen Länge durchgezogen werden und in den übrigen Teilen nicht durchgezogen werden.

10. Verfahren nach Anspruch 1, wobei die Andruckkraft mittels eines Andruckwerkzeugs aufgebracht wird.

11. Verfahren nach Anspruch 10, wobei die Metallfolien (11, 12) als Kühlflansche zur Kühlung der Vorrichtung (40) dienen.

12. Vorrichtung (40), die zum Gießen eines korrekten Gefälles in Richtung eines Bodenablaufs (41) verwendet werden soll, umfassend eine Bodenfläche (42), die der Neigung des Gefälles entspricht, und ein kreisförmiges Durchgangsloch (20) und einen Teil (44) zum Anschluss an den Bodenablauf, gekennzeichnet durch

- dass es ein Element (10) mit einer ersten (11) und einer zweiten (12) Platte aus Metallfolie, die parallel zueinander angeordnet sind, und einen Kern (13) aus einem Polymermaterial umfasst, der zwischen der ersten und der zweiten Platte angeordnet ist, wobei die erste Platte aus Metallfolie mehrere Rillen (21) aufweist, die entlang ihrer jeweiligen Länge zwischen dem Außenumfang der Vorrichtung (40) und dem kreisförmigen Loch (20) angeordnet sind, um es dem Polymermaterial des Kerns zu ermöglichen, bei der Zufuhr von Wärme zu dem Element (10) in die Rillen (21) auszufließen, und

wobei die Platten aus Metallfolie (11, 12) des Elements (10) durch Aufbringen einer Andruckkraft auf die erste Platte (11) nach der Wärmezufuhr zum Bilden der geneigten Form der Bodenfläche (42) der Vorrichtung (40) gebildet werden und gleichzeitig die Ränder des Lochs (20) nach unten gebogen werden, um einen rohrförmigen Teil (44) zu bilden, der zum Anschluss an den Bodenablauf (41) bestimmt ist, wobei das Polymermaterial in die Rillen (21) der ersten Platte (11) hinein in einer Zone (22) am Durchgang zu dem rohrförmigen Teil (44) in der Nähe des kreisförmigen Lochs (20) ausgeflossen ist.

13. Vorrichtung (40) nach Anspruch 12, dadurch gekennzeichnet, dass die Vorrichtung (40) eine Länge und eine Breite von 1000-1500 mm, bevorzugt 1100-1200 mm, aufweist, wodurch sichergestellt ist, dass ein Gefälle zu einem Bodenablauf (41) mit einer korrekten Neigung ohne spätere Anpassung des Gefälles hergestellt werden kann.

14. Verfahren zum Gießen eines Gefälles zu einem Boden in Richtung eines Bodenablaufs (41) unter Verwendung der Vorrichtung (40) nach den Ansprüchen 12 und 13, umfassend die Schritte des:

- Bereitstellens der Vorrichtung (40), die eine Bodenfläche (42), die der Neigung des Gefälles entspricht, und einen rohrförmigen Teil (44) umfasst, der an der Bodenfläche (42) zum Anschluss an den Bodenablauf (41) angeordnet ist;

- Anschließens der Vorrichtung (40) an den Bodenablauf (41) durch den rohrförmigen Teil (44);

- Bereitstellens von Nivellierschrauben (45), die in den Rillen (21) am Außenumfang des Elements (10) angeordnet sind und die durch den Polymerkern und die zweite Metallfolie (12) hindurchgehen;

- Ausrichtens der Vorrichtung (40) horizontal in Bezug auf den Boden und Einstellens der Vorrichtung (40) in Bezug auf den Boden mittels der Nivellierschrauben, um sicherzustellen, dass die Bodenfläche (42) der Vorrichtung (40) eine korrekte Neigung aufweist und diese beibehält;

- Zuführens von Fließspachtelmasse unterhalb der Vorrichtung (40), so dass der Zwischenraum (46) zwischen der Vorrichtung (40) und dem Boden gefüllt wird; und

- Abschneidens der Nivellierschrauben und Entfernens der Vorrichtung (40), wenn die Fließspachtelmasse sich verfestigt hat.

15. Verfahren nach Anspruch 14, wobei die Neigung der Bodenfläche (42) der Vorrichtung (40) in Bezug auf den Boden (43) durch die Rate eines ersten Wertes A und eines zweiten Wertes B bestimmt wird, wobei A als der Abstand zwischen der Mitte des Bodenablaufs (41) und einem äußeren Punkt an der Bodenfläche (42) der Vorrichtung (40) definiert ist und B als der senkrechte Abstand zwischen dem äußeren Punkt und dem Boden definiert ist.

Revendications

1. Procédure de fabrication d'un dispositif (40) comprenant une surface inférieure (42), un trou circulaire traversant (20) et une partie tubulaire (44) pour la liaison à un drain de sol, dans laquelle le dispositif est destiné à être utilisé pour couler une pente d'une inclinaison correcte vers le drain de sol (41), caractérisée par les étapes de :

- fourniture d'un élément (10) comprenant une première (11) et une deuxième (12) feuille de film métallique, lesquelles sont agencées parallèlement l'une à l'autre, et un noyau (13) d'un matériau polymère qui est agencé entre ladite première (11) et deuxième (12) feuille ;

- ménagement du trou circulaire traversant (20) de l'élément (10) ;

- réalisation de plusieurs rainures (21) dans ladite première feuille (11), lesquelles sont agencées le long de leurs longueurs entre la circonférence extérieure de l'élément (10) et le trou circulaire (20) pour permettre au matériau polymère de s'écouler dans les rainures (21) ;

- fourniture de chaleur à l'élément (10) ; et

- application d'une force de pression sur la première feuille (11) de film métallique pour former les feuilles (11, 12) de film métallique de sorte que la surface inférieure (42) de l'élément (10) correspond à une inclinaison qui fournit une pente correcte vers le drain de sol (41) et, simultanément, pour plier le bord du trou circulaire pour former la partie tubulaire (44) destinée à être reliée au drain de sol (41), dans laquelle le matériau polymère s'écoule dans les rainures (21) de la première feuille dans une zone (22) au niveau du passage vers la partie tubulaire (44) près du trou circulaire (10).

2. Procédure selon la revendication 1, comprend en outre l'application d'un revêtement foncé, tel qu'une couleur noire ou une couche de film foncée, sur ladite zone (22) entourant le trou circulaire (20) de l'élément (10) avant que la chaleur soit fournie pour augmenter la capacité d'absorption de la chaleur dans cette zone (22) lors de la fourniture de chaleur et augmenter ainsi sa formabilité.

3. Procédure selon la revendication 1 et 2, dans laquelle la chaleur est fournie par rayonnement, tel qu'un rayonnement IR, induction, convection ou conduction.

4. Procédure selon la revendication 1, dans laquelle le trou circulaire (20) est agencé au centre de l'élément.

5. Procédure selon la revendication 1, dans laquelle 4 à 16 rainures (21) sont agencées dans la première feuille (11).

6. Procédure selon la revendication 1 et 5, dans laquelle les rainures (21) sont agencées symétriquement entre la circonférence extérieure de l'élément (10) et le trou circulaire (20).

7. Procédure selon la revendication 1, 5 et 6, dans laquelle les rainures (21) sont réalisées avec une largeur de 1 à 10 mm, de préférence 2 à 6 mm.

8. Procédure selon la revendication 1, et 5-7, dans laquelle les rainures (21) sont réalisées traversantes le long de leurs longueurs.

9. Procédure selon la revendication 1 et 5-7, dans laquelle les rainures (21) sont réalisées traversantes dans une ou plusieurs parties de leurs longueurs, et sont réalisées non traversantes dans les parties restantes.

10. Procédure selon la revendication 1, dans laquelle la force de pression est appliquée au moyen d'un outil de pressage.

11. Procédure selon la revendication 10, dans laquelle les films métalliques (11, 12) servent de brides de refroidissement pour refroidir le dispositif (40).

12. Dispositif (40) destiné à être utilisé pour couler une pente correcte vers un drain de sol (41) comprenant a surface inférieure (42), laquelle correspond à l'inclinaison de la pente, et un trou circulaire traversant (20) et une partie (44) pour la liaison au drain de sol, caractérisé en ce que

- il comprend un élément (10) avec une première (11) et une deuxième (12) feuille de film métallique, lesquelles sont agencées parallèlement l'une à l'autre, et un noyau (13) d'un matériau polymère qui est agencé entre ladite première et deuxième feuille, dans lequel ladite première feuille de film métallique a plusieurs rainures (21) lesquelles sont agencées le long de leurs longueurs entre la circonférence extérieure du dispositif (40) et le trou circulaire (20) pour permettre au matériau polymère du noyau de s'écouler dans les rainures (21) lors de la fourniture de chaleur à l'élément (10), et

dans lequel les feuilles de film métallique (11, 12) de l'élément (10) sont formées par application d'une force de pression sur la première feuille (11) après la fourniture de chaleur pour former la forme inclinée de la surface inférieure (42) du dispositif (40) et simultanément les bords du trou (20) sont pliés vers le bas formant une partie tubulaire (44) destinée à la liaison au drain de sol (41), dans lequel le matériau polymère s'est écoulé dans les rainures (21) de la première feuille (11) dans une zone (22) au niveau du passage vers la partie tubulaire (44) près du trou circulaire (20).

13. Dispositif (40) selon la revendication 12, caractérisé en ce que le dispositif (40) a une longueur et une largeur de 1000-1500 mm, de préférence 1100-1200 mm, ce qui garantit qu'une pente vers un drain de sol (41) d'une inclinaison correcte peut être fabriquée sans ajustement ultérieur de la pente.

14. Procédé pour couler une pente sur un sol vers un drain de sol (41) en utilisant le dispositif (40) selon la revendication 12 et 13, comprenant les étapes de :

- fourniture du dispositif (40) comprenant une surface inférieure (42) laquelle correspond à l'inclinaison de la pente et une partie tubulaire (44) qui est agencée au niveau de ladite surface inférieure (42) pour la liaison au drain de sol (41) ;

- liaison du dispositif (40) au drain de sol (41) par ladite partie tubulaire (44) ;

- fourniture de vis de nivellement (45) lesquelles sont agencées dans lesdites rainures (21) au niveau de la circonférence extérieure de l'élément (10) et lesquelles traversent le noyau polymère et ledit deuxième film métallique (12) ;

- alignement du dispositif (40) horizontalement par rapport au sol et réglage du dispositif (40) par rapport au sol au moyen des vis de nivellement pour garantir que la surface inférieure (42) du dispositif (40) a et maintient une inclinaison correcte ;

- fourniture de mastic flottant en dessous du dispositif (40) de sorte que l'espace intermédiaire (46) entre le dispositif (40) et le sol est rempli ; et

- coupe des vis de nivellement et retrait du dispositif (40) lorsque le mastic flottant s'est solidifié.

15. Procédé selon la revendication 14, dans lequel la pente de la surface inférieure (42) du dispositif (40) par rapport au sol (43) est déterminée par le taux d'une première valeur A et d'une deuxième valeur B, dans lequel A est défini comme la distance entre le centre du drain de sol (41) et un point extérieur au niveau de la surface inférieure (42) du dispositif (40), et B est défini comme la distance perpendiculaire entre ledit point extérieur et le sol.

Drawing