The present invention relates to a method for creating a floor layer with a predefined inclination angle on a subfloor. The present invention further relates to a device for creating a floor layer with a predefined inclination angle on a subfloor. A known technique for making a bathroom floor that is to be finished later with tiles comprises freely casting over a subfloor, or pouring thereon, a layer of mortar, and levelling the mortar layer with a straightedge. After hardening, the mortar forms a relatively hard, strong, and flexurally stiff floor layer, that thus forms a good subsurface for tiles to be applied.

For creating a bathroom or shower floor with a slope, relatively dry mortar is used, that is levelled freehand under an angle.

A drawback of the described method is that the levelling, especially under an angle, is rather time-consuming if the floor eventually obtained is to be able to form a subsurface sufficiently level and smooth to be able to be tiled well. Another drawback is that the free casting or pouring of mortar requires a relatively large quantity of mortar, in relation to the minimal thickness that a created floor layer is required to have, if the floor layer is to be insusceptible to fracture. The created floor layer is thereby also relatively thick.

The present invention aims to provide a solution to at least one of the problems mentioned above. More in general, the present invention aims to provide a method for creating a floor layer with a predefined inclination angle on a subfloor, which method is more quickly and more easily applicable than already existing methods with that purpose, and which is thereby for instance relatively easily applicable by a DIY person without much or specific experience in accurate levelling or straight- edging of mortar layers, and a method that offers at least the possibility of creating a floor layer that is relatively thin, but that is nevertheless relatively insusceptible to fracture, with relatively little mortar or other hardening material.

At least one of the above objectives is attained by a method comprising the steps of placing an element on the subfloor, comprising a framework of which a top face and a bottom face are inclined with respect to each other, which framework comprises an outer frame and a structure of inner walls, surrounded by the outer frame, that define a plurality of cells extending over the height of the framework, which cells are open at least at the top side of the framework; filling the cells with a hardening filling material maximally up to a top edge of the framework that is located in the top face, and letting harden the filling material.

In a method according to the invention, the top face of the floor layer created is defined by the top face of the framework of the element placed on the subfloor. As a result, the top face of the floor layer is defined relatively accurately, without a time consuming freehand straightedging operation being required for that.

Nevertheless, after application of the filling material such as mortar, the top face or another reference face of the framework may be skimmed, for instance with a straightedge, for removing, levelling or pressing into the cells of any excess filling material and levelling the applied mass of filling material. In that way, the cells can be filled relatively quickly and efficiently, wherein the filling is measured up to the top edge or another reference level. A floor layer created with a method according to the invention is relatively

insusceptible to fracture, as a result of hardened pieces of filling material therein being smaller than the entirety of hardened material in a floor layer of comparable dimensions, completely consisting of hardened material. A floor layer created with a method according to the invention can thereby be formed relatively thin, wherein also relatively little hardening material is required.

An efficient and relatively quick filling of the cells may also take place by providing a liquid filling material, and pouring that into the cells. Any excess filling material can thereby run over the top edge of the framework, in which case the filling automatically will not reach higher than the top edge. As a possibility, also in this case the top face of the framework may be skimmed, to remove filling material lying on the top face.

An interior cell volume of the cells remaining in between the filling material and the top edge after applying the filling material may still be filled with a certain material, preferably after complete or partial hardening. In that way, in case of a framework having a sloping top face, it suffices to use a liquid filling material, of which the liquid level in that case will not be able to stretch till the top edge at every position within a cell. Preferably, the inner wall structure has a honeycomb shape, hence with hexagonal cells, that gives a certain sturdiness to the element and to the eventually created floor layer. Preferably, the element, or at least the framework is formed in one piece, so that at least the strength of the eventually created floor layer is not unnecessarily weakened by joints that are present in the element or in the framework.

A preferable material for the element, or at least the framework is plastic, by which the element can be relatively lightweight and can also be handled relatively easily.

The top face may comprise different parts that slope towards a same area from different directions, so that a floor layer having a slope from different directions toward that same area is created. Said different directions may for instance be mutually opposite directions, or directions that are angled with respect to each other for instance by 90 degrees.

Said same area may be located within the framework, at an edge of the framework, and at a corner of the framework, depending on whether slope from different directions toward one of those locations is desired.

An opening may be provided in said same area, within which a draining device is placed. A draining device, or at least a plate, gutter or box shaped portion with an outlet opening for letting out drained water, located inside or outside the framework, may also be molded to the framework, and/or (in that way) constitute an integral part of the framework. The element may be provided with adjusting feet for height adjusting or inclining the framework with respect to the subfloor, so that the framework as a whole may be inclined with respect to the subfloor. By adjusting the adjusting feet, for instance, any additional slope may be created, or unevenness in the subfloor make taken into account in placing the element.

At least some of the cells may be open also at the bottom side of the framework, so that applied mortar can come into contact with the subfloor, so as for instance to obtain a good adherence of the created floor layer with the subfloor. However, the framework may also have a completely closed or at least partially open bottom. A closed bottom can prevent applied filling material from running out of the framework when for instance a liquid filling material is used. Any present openings in the bottom may however still cause applied filling material to adhere to the subfloor.

In the case that the framework is at least partially open at the bottom side, the element may comprise a membrane that covers the framework at the bottom side, or at least covers openings of the cells in the bottom face, which membrane can serve to keep contained filling material in the framework, or at least cause it to not flow away from under the framework.

The membrane may comprise a mesh, that through its openwork character can cause adherence of the filling material contained in the framework to the subfloor. The membrane may seal off one or more cells individually, to keep contained filling material within the respective cells.

However, the membrane may also be partly separate from the framework, so that filling material from certain cells can flow till under the framework, still separated from the subfloor by the membrane, so as to cancel unevenness of the subfloor.

For improved adherence of the filling material to the subfloor, larger holes may be provided in the membrane. The method according to the invention may further comprise the steps of placing multiple elements of the described type next to or on top of each other, and preferably fixing those with respect to each other. In that way, with multiple elements, a larger structure can be formed relatively quickly, that can then be filled with filling material to create a larger floor layer.

The framework of at least one of the element may in that case be placed on the framework of another element, which other element has a top face and a bottom face that lie in parallel with each other. In that way, multiple elements having a sloping top face can be placed behind each other at different, to obtain a floor layer with a slope over a longer distance.

The outer frame may have two portions located on opposite sides of the element, that are formed complementary to each other. In that way, multiple elements placed next to each other can be fitted into each other to form a larger floor layer. For interconnection of multiple elements in a floor layer, an element may have coupling parts formed complementary to each other located on opposite sides of the element for coupling to a neighboring element. The outer frame may protrude above the inner wall structure at one or more, and preferably all sides of the framework, so that the outer frame can form a water barrier there when the floor is finished.

Further advantageous combinations of steps of a method according to the invention, as well as advantageous combinations of features of a device, in the form of an element as described, that is especially destined for use in said method, are described in the following descriptions of the figures, and in the appended claims.

The invention is described in more detail with reference to the drawing, in which: - Figures 1 a to 1 d schematically illustrate different steps of a method according to the invention, wherein a floor layer having a predefined inclination angle is created with the help of filling material in the form of relatively dry mortar;

Figures 2a and 2d schematically illustrate a method according to the invention, wherein a floor layer having a predefined inclination angle is created with a filling material in the form of liquid mortar, and

Figures 3 to 14 show different embodiments of a device for use in a method according to the invention.

With reference to Figure 1 a, in creating a floor layer having a predefined inclination with the help of relatively dry mortar, an element 1 is placed on a subfloor 100, comprising a framework 10, 30.

The framework 10, 30 comprises an outer frame 10 demarcating on the subfloor 100 an area within which the mortar is to be applied. An interior volume 20 of the element 1 , surrounded by the outer frame 10, and within which the mortar is to be received, is subdivided by smaller rooms, or cells 21 , by a structure of inner walls 30 forming a part of the framework 10, 30.

The element 1 may be bottomless, so that the element 1 only comprises the framework 10, 30 existing of the outer frame 10 and the inner wall structure 30. The bottom 41 of an individual cell 21 then is formed by a part of the subfloor 100.

However, the element 1 may also itself have a bottom, in which case the bottom 41 of an individual call 21 is formed by a part of that larger bottom of the element 1 , wherein each cell 21 itself is box shaped. At the top side of the framework 10, 30, the cells 21 formed by the outer frame 10 and the inner wall structure 30 are open, so that mortar can be received in each of the cells 21 via a top face 50 of the framework 10, 30. In the shown example, the respective top edges 1 1 , 31 of the outer frame 10 and the inner wall structure 30 lie in a same plane, and more in particular in the top face 50 of the framework 10, 30. The top face 50 is angled with respect to the bottom face 40 of the framework 10, 30, with which bottom face 40 the framework 10, 30 is placed on the subfloor 100, so that after placement of the element 1 on the subfloor 100, the top face 50 of the framework 10, 30 is also angled with respect to that subfloor 00. Each cell 21 extends in that case over the full height of the framework 10, 30, between the bottom face 40 and the top face 50.

With reference to Figure 1 b, a quantity of relatively dry mortar 200 is poured out over the framework 10, 30.

With reference to Figure 1 c, then, the top face 50 of the framework 10, 30 is skimmed with a straightedge 300, for pressing smaller quantities of mortar 201 into the individual cells 21 via the top face 50, and for brushing an excess quantity of mortar 202 off of the top face 50 with the straightedge 300.

With reference to Figure 1 d, after that, a combination remains of the framework 10, 30 and the smaller quantities of mortar 21 contained in the cells 21 , that reach in each of the cells 21 till the top face 50 of the framework 10, 30, in which top face 50 the top edges 1 1 , 31 of the outer frame 10 and the inner wall structure 30 are situated. Said mortar quantities 201 and said top edges 1 1 , 31 thereby form a composite surface in the top face 50 of the framework 10, 30 that, at least after hardening of the mortar quantities 201 , is level and accurately arranged under a certain angle with respect to the subfloor 100, and that thus is well suited to be tiled.

With reference to Figure 2a, in creating a floor layer with the help of liquid mortar 400, a quantity of mortar 400 is casted over the framework 10, 30 of an element 1 placed on a subfloor 100 as has already been described with reference to Figures 1 a to 1 d. The mortar 400 may in that case be casted directly into the calls 21 , or distribute itself over different cells 21 by overflowing over the edge 31 of the inner wall structure 30 of the framework 10, 30.

With reference to Figure 2b, after any straightedging of the top face 50 of the framework 10, 30 for cleaning the top edges 1 1 , 31 thereof, the framework 10, 30 remains with smaller mortar quantities 401 contained in the cells 21 formed by it, of which the liquid level may be different for each cell 21 , depending on the position of a respective cell 21 in the framework 10, 30 and the minimal height of the portion of the top edge 1 1 , 31 surrounding that cell 21 .

With the top edges 1 1 , 21 , of the framework 10, 30 extending in the sloping top face 50 of the framework 10, 30, an interior volume 22 remains in a cell 21 filled with liquid mortar 400 above a mortar quantity 401 in that cell 21 , which after partial or complete hardening may still be filled with a certain material, for letting tiles to be applied on the top face 50 rest well on or adhere to the deeper lying mortar quantities 401 in each of the cells 21 .

In Figures 1 a to 1 d and Figures 2a and 2b, an element 1 for use in a method according to the invention is only shown schematically, as an element 1 having a framework 10, 30 comprising cross-sectionally rectangular, and in particular square cells 21 .

In Figure 3, an element 1 or use in a method according to the invention is shown in a more realistic shape, having a framework 10, 30 comprising a structure of inner walls 30 comprising cross-sectionally hexagonal cells 21 , so that the framework 10, 30 has a honeycomb shape, as a whole, or at least with respect to certain parts thereof.

An angle between the bottom face 40 and the top face 50 may provide a slope of, for instance, 1 cm per meter, 2 cm per meter, or a value in between. An optimal value will be one at which the criterion is fulfilled, that, on a floor layer once finished, water will be able to flow away with sufficient ease towards a drain, or that of certain customs in the profession, possibly based on regulations.

The openings in the top face 50 of the framework 10, 30 formed by the cells 21 may have a diameter of, for instance, 1 or 2 cm, up to a maximum of, for instance, 6 cm, or a value in between. At least in the case of the cells 21 extending over the full height of the framework 10, 30, the cells 21 having a uniform shape or diameter over the full height, a smaller diameter of the openings will provide smaller cells 21 , and thereby a more sturdy framework 10, 30. Larger diameters, on the other hand, facilitate the filling process: then, the filling material flows in more easily, or is pressed in more easily. The. element 1 , in whatever shape, or at least the framework 10, 30 thereof, is preferably formed in one piece, preferably from plastic, for instance by injection molding. In the element 1 as shown in Figure 3, two portions 12, 13 of the outer frame 10 located on opposite sides of the element 1 are profiled and formed complementary to each other, so that multiple specimens of the shown element 1 can fittingly laid against each other to form a larger floor layer. With reference to Figure 4, an element 1 as described may comprise a shower gutter or other draining device 70, or at least a plate, gutter, or box shaped portion with an outlet opening 71 for letting out water, which is molded to that framework 10, 30. In the embodiment shown in Figure 4, this draining device 70 lies outside, and more in particular along an edge 14 of the framework 10, 30, but it is also possible that a draining device 70 as part of the element 1 is formed inside, or surrounded by the framework 10, 30, or at least inside the outer frame 10.

With reference to Figure 5, two portions 12, 13 of the outer frame 10 located on two opposite sides of the element 1 may also be flat, so that multiple elements 1 can be placed with their side portions 12, 13 flatly against each other.

With reference to Figure 5, furthermore, the top face 50 of the framework 10, 30 may comprise different portions 51 , 52 that slope from different directions, inclined with respect to a bottom face 40 of the framework 10, 30, towards a same area 53, to create a lower portion of a floor layer to which water can flow.

With reference to Figure 6, in an area 53 that portions 51 , 52 of the top face 50 slope toward from different directions, and within the framework 10, 30, a larger opening 60 may be present (or be provided, by cutting away part of the framework 10, 30), in which a draining device such as a shower gutter can be placed.

In the examples of Figures 5 and 6, said same area 53 is located centrally within the framework 10, 30, in between parts 51 , 52 of the top face 50 sloping from opposite directions, but said same area 53 may also lie at an edge of the framework 10, 30, or at a corner thereof, and inside or outside the outer frame 10.

Figure 7 shows an embodiment in which said same area 53 lies at an edge, and more in particular at a corner of the framework 10, 30, outside the outer frame 10, in the shown example, wherein said different portions 51 , 52 of the top face 50 slope toward that area 53, while separated by a diagonal of the framework 10, 30, in the shown example, in directions that are angled with respect to each other, wherein, in the shown case, again an opening 60 is present in said same area 53, in which a draining device can be placed.

With reference to Figures 8 to 11 , the element 1 may, in a practical embodiment, further have one or more of the following features, alone or in combination:

a bottom 90 that fully seals off the framework 10, 30 at the bottom side, and that is possibly integrally formed with the framework 10, 30 (see Figure 8);

- one or more adjusting feet 75 for height adjusting or inclining the framework 10, 30 with respect to the subfloor 100 (see Figure 8);

a membrane 80 covering the framework 10, 30 at the bottom side, which membrane 80 may individually seal off one or more cells 21 , which membrane may be a mesh, and in which membrane 80 a larger holes 81 may be provided (see Figure 9);

a partially open bottom 90 at the bottom side of the framework 10, 30, having therein one or more openings 91 that a cell of the framework 10, 30 opens into (Figure 10);

a membrane 80 covering the framework 10, 30 at the bottom side, which membrane 80 is at least partly separate from the framework 10, 30 or from a bottom 90 above that membrane 80, whether or not present and whether or not open, and which membrane may be adhered to a bottom edge of the outer frame 10 (see Figure 11 ). With reference to Figure 12, a floor layer having a slope extending over a larger distance may be created by placing behind each other two elements 1 having a sloping top face 50, wherein a back one of the two elements 1 is placed on top of an element 2 of a second type, which second type of element 2 has a framework 201 , 230 with an outer frame 210 and an inner wall structure 230, of which a top face 250 and a bottom face 240 lie in parallel to each other. In that way, the back element 1 of the first type comes to lie at a higher level, and the sloping top faces 50 of the two elements 1 of the first type together form a larger sloping surface. The element 1 of the first type that is placed on top of the element 2 of the second type is preferably open at the bottom side, for letting material that is filled into the framework 10, 30 thereof flow till inside the framework 210, 230 of the element 2 of the second type. The element 2 of the second type may further have all features of an element 1 of the first type, or features that are identical to features of the element 1 of the first type that is placed directly onto the subfloor 100. With reference to Figure 13, two elements 1 a, 1 b, whether or not of the same type, may be provided with complementary formed coupling parts 15, 16 for mutually coupling the two elements 1a, 1 b when those are placed next to each other. In the shown example, a first coupling part 15 is formed as a turned upper edge of the outer frame 10a of a first element 1 a, and a second coupling part 16 is formed as a preferably somewhat recessed upper edge of the outer frame 10b of the second element 1 b. A coupling is established in that case by hooking the first coupling part 15 to the second coupling part 16. Preferably, each element 1a, 1 b comprises two coupling parts 15, 16 located on opposite sides of the element 1a, 1 b that are complementary to each other, so that, using those, two or more elements 1a, 1 b may be coupled to each other in a row.

With reference to Figure 14, a further embodiment of an element 1 for use in a method according to the invention comprises a framework 10, 30 comprising an outer frame 10 and an inner wall structure 30, wherein, at least along certain portions of its circumference, the outer frame 10 extends above the inner wall structure 30. The protruding parts 17 of the outer frame 10 thus formed may form a water barrier, and may for instance be accommodated behind a wall finishing. It is noted, that an element for use in a method according to the invention need not necessarily be used as a whole to be filled with a certain material, and to become part of a created floor layer. The element may also be cut to size first, wherein, by a transverse cut through the framework, the outer frame is completely or partially removed at one or more sides of the element. In case the remaining part of the framework is subsequently positioned onto a subfloor and filled with a certain material, on a side of the element where a part of the outer frame has been removed, a most outwardly lying part of the inner wall structure functions as (at least part of) an outer frame, preventing filling material from flowing away outside an area demarcated by the element. Possibly, also a wall located outside the element may fulfill that that function, next to which wall that element is placed.

It will be clear to a skilled person, that the invention is not limited to the embodiments discussed in the foregoing, but that several variants and modifications are possible within the scope of protection of the invention as defined in the appended claims. Even in case features have been mentioned in different independent claims, the present invention also relates to an embodiment having these features in common. Even in case certain features have been described in combination with each other, the present invention also relates to an embodiment in which one or more of those features have been omitted. Features that have not been explicitly described as essential, may also be omitted. Any reference numbers used in a claim are not to be construed as limiting to the scope of that claim.

For the purpose of clarity, it will be specified here, that with a cell being open at the top side of an element, it is meant that the cell opens into the top face of the element, or that the cell has an opening located in the top face of the element. Similarly, a cell that is open at the bottom side of the element opens into the bottom face of the element. The top face and the bottom face are especially meant to be the top face and the bottom face of the inner wall structure of the framework, as that outer frame locally may extend above the inner wall structure.

Extending over the height of the element of a certain cell is especially meant to mean extending over at least part of the distance between the bottom face and the top face of that cell. Filling a cell maximally up to a top edge of the framework means, that the cell is filled maximally up to an edge surrounding the opening of the cell located in the top face.