Jig for forming a cement base

Abstract

A jig 10 configured for forming a cement base, wherein the jig comprises; frame comprising; a plurality of walls 20A, 20B, 20C, 20D connected to form a hollow loop, wherein each of the walls has the s

Description

Background In construction when forming a tile floor, it is necessary for a user to first lay a cement base over the area to be tiled before mounting the tiles onto the surface. In some cases, a user may lay cement over the entire area this ensures that all the cement in the area is level to a consistent height. However, this method may make it difficult for a user to place the tiles once the cement is laid, as the user may need to step onto the drying cement to place one of the tiles thereby disturbing the surface of the cement which may result in the cement base no longer being level across the entire desired area. In other cases, a user may place cement over a portion of the desired area at a time. This allows the user to walk over the area that has no cement when positioning the tiles onto the cemented area, thereby reducing the risk of the user stepping onto the drying cement after it has been laid. However, as the cement is placed in sections, there is a risk of the cement base in one area not aligning with the cement base in the adjacent area. Both the disturbances to the cement surface and the misaligned cement bases can result in the tiles placed onto the cement base being uneven. This may result in one or more of the tiles breaking as they are not properly supported. Alternatively, this may result in tiles being misaligned, such that a tile is higher or lower than the adjacent tiles, this results in breaks in the tiled floor which may be a tripping hazard to the user. Therefore, there is a need to provide an improved method of laying cement bases that can ensure that the cement base is level all across the desired area, without the need to cover the entire area at once, thereby allowing the user to place tiles onto the area without needing to step onto the drying cement. Such a method would provide an improved finish to the tile floor as the level cement base would ensure the tiles laid over the base are also level across the tiled area. This in turn reduces the risk of tiles being damaged or a user tripping and being injured when walking over the tiled area. Summary The present invention provides a cementing frame for preparing a desired area for mounting a tile. More specifically, the claim invention provides a frame that can be used for laying cement over a desired area which can then be used to mount one or more tiles. Wherein the frame comprises a hollowed frame with the same shape as the tiles that the user wishes to lay, such that the frame comprises the same number of sides as the desired tiles being used, with sides with lengths equal to the side of the tile. Alternatively, when using a plurality of small tiles or tile chipping the frame may instead have the shape of the desired area the user wishes to place the tiles onto. In use, the user would lay the frame over the desired area, then the user may fill the hollow space in the center of the frame with cement, using the walls of the frame to restrict the cement to the desired area. Then the user may use the walls of the frame and a suitable tool, such as a trowel or float to level the cement to the height of the frame, scraping the cement within the frame, to ensure the surface of the cement is level and that the cement has the same height as the walls of the frame. This method produces a level cement base that one or more tiles may be mounted to, the frame not only ensures that the cement base is level to a desired height but would also ensure that the tile is level to adjacent tile as each tile would be mounted to a cement base with the same height. Further, at least one side of the frame may include a mounting lip, wherein said mounting lip extends outwards from the edge of the frame. In some cases, the lip would be level with the top of the frame edges, in these cases, the lip would rest on an adjacent cement base to ensure that the cement base within the frame is level with the adjacent cement base to ensure that all the tiles will be at the same height when placed onto the cement base. However, it is noted that this lip may become stuck to the surface of the adjacent cement base, or may disturb the surface of the adjacent cement base resulting in the edge of the base no longer being level with the rest of the base. Therefore, the preferred design for the mounting lip would extend vertically upwards from the wall of the frame as well as outwards from the frame. In these cases, the lip would rise upwards from a frame at a distance equal to the thickness of the tiles being laid onto the cement base. This way the lip of the frame rests on the surface of the tile placed over the adjacent cement base. This still ensures that each cement base is level to a certain height, and further ensures that each of the tiles laid onto the cement bases is level with a second height, such that all of the tiles in the tiled area are level. In some cases, one or more of the frame walls may include an inward-facing lip extending from the top edge of the wall. This lip acts as a guide limiting the height of the cement base to a desired height and ensures that when the cement is leveled using a suitable tool the surface of the cement base is level with the desired height equal to the height of the inward lip. And in some cases, the frame with these inwards lips may be used as a guide for placing a tile onto the cement base. Once the cement base is formed the user may remove the frame, place the tile onto the cement base, and then replace the frame over the cement base ensuring that the sides of the tile align with the sides of the cement base, the user may then apply force to the lip of the frame to push the tile down onto the cement base secure the tile in place with the desired alignment. This lip also allows force to be applied even to the edges of the tile as the pressing force, for example from the user or a mallet would be distributed over the length of the lip reducing the risk of the edges of the tile breaking. In some embodiments, the lips attached to the frame may be adjustable to allow a single frame to be adjusted to lay tiles at different heights or to allow the frame to be used for tiles of different thicknesses, as described above. In such cases, the lips by being connected to a rachet rail allow the height of the lips to be adjusted to one of several predetermined heights. And in some cases, the outward lips may be configured to be removable and may be configured to be both removable and adjustable. This may be useful when forming a cement base for a tile at the edge of the tiled area, wherein the floor adjacent to the tile may be a different height, or wherein the tile may be adjacent to a wall. In both of these cases, an outward lip may obstruct the frame’s placement. Therefore, in these cases, the outwards lip could be adjusted to match the height of the adjacent area, or removed completely when the lip cannot match the level of the surrounding ground or when the tile is adjacent to a wall. The preferred embodiment of the frame would comprise one or more hinges or pivoting points that would be configured to allow the frame to hold at each of these points to allow the frame to be flattened for easier storage. In some cases, the corners of the frame would comprise the above-mentioned hinges to allow the frame to collapse into a linear shape to minimize the volume of the frame for easier storage and transportation. In some cases, the walls of the frame may be extendable, wherein the sides include telescopic walls, sliding rails, and / or ratcheted rails which allow the sides of the frame to be extended. This allows a single frame to be adjusted to cover differentsized areas allowing the frame to be used with a wider variety of tiles, by making the frame larger or smaller to match the size of the tiles being used. Further, these adjustable sides may be used in conjunction with the folding points described above to further reduce the size of the frame when stored. Regardless of the size of the frame, it is preferable for the frame to comprise a material that is strong, so that it does not wear or break easily after repeated uses, and is also lightweight to be more easily carried and transported by the user. Further, the material would need to be chemically resistant as the frame would be in contact with the wet cement used to form the base, therefore the material must be water resistant and would also be inert with the cement. With these factors in mind, the frame may be made from thin pieces of metal, such as steel which is both strong and chemically resistant, or lighter metals such as aluminum to reduce the overall weight. Though of these options, the stronger steel is preferable. Further, the walls of the frame may be covered in a coating to help prevent the drying cement from clinging to the frame, because if the cement was to stick to the frame it may distort the cement base when the frame is removed. As noted in use a user would first lay the jig’s frame over a portion of the area to be tiled. Once in position, the user would fill the inside of the frame with cement such that the cement reaches the top of the frame walls, or the surface of the inwards lip if present. Once the cement is at the desired level the user may use a tool such as a trowel or float to level the cement in the frame with the desired height, which in this case would be equal to the height of the frame or the height of the inward lip. After the cement is level, the user can simply lift the frame away from the cement, leaving behind a cement base onto which tiles can be placed. Once the base is formed the user can simply place the tile over the cement base and press it down into position so that the cement surface grips the underside of the tile. In cases where the frame includes an inward lip, the user may place the jig frame over the tile and cement base, using the walls of the frame to align the tile and apply force to the inward lip to force down the edges of the tile. Using this method, the pressing force is distributed over the lip thereby reducing the risk of the tile edges breaking, and reducing the risk of the tile slipping out of place when being pressed down by the user. The process above is then repeated for each section of the desired area until the entire area has been covered. Note that in cases where the frame includes an outward lip, the user may rest the outward lip onto an adjacent tile or cement base to ensure the frame is at the same height for each section of the desired area, this ensures that all the cement bases are level with one another, thereby ensuring the tiles are also level. However, it is preferable that the outer lips be removable as the tiles at the edges of the desired area may be adjacent to a wall, or other features that would obstruct the positioning of the frame as the outer lip would press against the obstructing feature. It is preferable that the outer lip is not only removable but also adjustable allowing the user to set the outer lip to different heights to allow the frame to be used with tiles of different thicknesses. By using the frame as described above the user can ensure that the cement laid in the desired area is level across all the sections of the area, and can therefore ensure that the tiles placed onto the cement bases are level across the tiled area too. Detailed description The present invention is illustrated in the following drawings: Figure 1 depicts a jig as per the claimed invention in the unfolded position Figure 2 depicts the jig of Fig. 1 in a half-folded position Figure 3 depicts the jig of Fig. 1 in the folded position Figure 4 depicts a schematic drawing of the sides used to form the jig of Fig. 1 Figure 5 depicts an example profile for the sides of the jig. Figure 6 depicts an example of how the sides of the jig may be attached at the corner of the jig. Figures 7a, 7b, and 7c depict a user unfolding the claimed jig as displayed in Figs. 1, 2, and 3. Figure 8 depicts a user using the claimed jig by placing it over the desired area. These figures comprise the following feature, please note that like features are indicated by like reference numerals: 10 - Jig (open) 12 - Jig (half-folded) 14,14’ - Jig (folded) 20 - Jig side 30 - side lip 40 — Aperture Figure 1 depicts an example of a rectangular jig 10 as per the present invention. More specifically, the present invention provides a jig configured for forming a cement base suitable for laying tiles over a desired area. Wherein the jig 10 comprises a hollow frame, and in use this frame would be placed over the desired area such that the user may pour cement into the frame trapping the cement between the sides 20 of the jig. Once the cement is poured into the jig 10 the user may use a suitable tool to level the cement with the top of the sides of the frame 20. Such tools may include a trowel, float, or spirit level which can be passed over the cement and jig 10 to level the cement with the frame to a desired level determined by the height of the jig’s sides 20. Once the cement has been leveled, the user may simply lift and remove the jig leaving behind a cement base. Once formed the user can simply lay the desired tile onto the cement base to secure the tile in place. By using the jig 10 as described above, the user can place the cement base over a portion of the desired surface at a time, similarly allowing the user to tile a portion of the desired surface as they place the cement base. This is desirable as this method means that the user no longer needs to place the cement base over the entire area at once. Covering the entire area may make it more difficult for the user to level the cement base, especially as the user would not be able to walk over the cement base without displacing the cement beneath them. It is also noted that attempting to place the cement in sections without the jig 10 may result in the adjacent bases not being level resulting in an uneven surface. By using the jig 10 the user can ensure that the cement base formed over the desired area is level thereby ensuring that the tiles placed on the cement will similarly be level, reducing the risk of the finisher surface being uneven, thereby reducing the risk of a personnel tripping and falling when walking over the finished tiled surface. It is also noted that the depicted jig 10 includes a lip 30 on some of the sides of the frame. Wherein the lip 30 extends outwards from the top of the frame sides 20. In use, the user would rest the lip on the surface of the adjacent cement base, or a surface surrounding the desired area, to ensure that the frame is positioned such that the top of the frame sides 20 is level with the adjacent cement base or the area surrounding the area to be tiled. This further ensures that the cement base formed with the claimed jig 10 is level across the entire desired area. Though not depicted it is also noted that the jig 10, may comprise an inward lip, which extends inward from the top of the frame sides 20. This inward lip can be used to determine the level of the cement base formed within the jig 10. Such that the user would fill the frame to a point where the cement reached the inward lip, and then level the surface of the cement to the level of the inward lip. This may be useful in cases wherein the outward lip 30 is not configured to rest upon an adjacent cement base but instead rests on an adjacent tile. For, in some methods, the user may place the tile onto the created cement base before forming the adjacent base, this way the user may walk on the tiled parts of the desired area while forming the subsequent cement bases, thereby ensuring the user can still walk through the desired area as they work without stepping onto the cement. However, in this method the tile placed on top of the cement base would be taller than the cement base alone, thus there is a need for two lips at different heights, one at the height of the tile and one at the desired height of the cement base. It is also noted that the inward lip may be used to place the tile onto the cement base. More specifically, once the cement base is formed, the user may place the tile over the cement base, and then place the jig 10 over the tile and cement base. The placing of the jig would help to ensure that the tile is correctly aligned with the cement base. Further, the inward lip may be used to apply force to the edge of the tile, evenly pressing the tile down into the cement base, thereby ensuring that the tile rests level on the base and reduces the risk of the tile breaking while being placed as the force is dissipated over the entire edge of the tile via the frame. Figures 2 and 3 depict how the jig 10 from Fig. 1 may be folded for ease of transport and storage. More specifically, Fig.3 depicts the jig 10 when completely folded, in this case, the rectangular frame of the jig 10 is collapsed to form a linear bar that can be more easily stacked for storage or transit. Fig. 2 depicts an intermediate stage of the folding process used for the depicted jig 10. In the depicted example, opposite corners of the frame are pulled outwards, thereby forcing the remaining corners to widen as they are pulled toward the center of the frame. Eventually, the widening comers meet, leaving the frame as a linear bar as the hollow center is completely collapsed. It can be seen in Fig.2 that the corners of the jig are configured to pivot thereby allowing the frame to fold and collapse. It should be noted that even though the frame depicted in the figures is rectangular the claimed jig 10 may have different shapes as required. It is also noted that the sides of the frame may have different sizes to match the size of the tiles being used. Regardless of the shape or size of the frame, the jig 10 would preferably be configured to be foldable, such that the frame can be collapsed for easier storage. This would be achieved by having pivoting corners like those shown in the depicted example, it should be noted that one side of the frame lacks a lip to allow the frame to collapse completely, in some frames all sides may include a lip though such a frame would not collapse completely it may still fold down to make storage easier. In other cases, especially for frames with more sides, there may be multiple sides without a lip to allow the frame to collapse when folded. Figure 4 shows the sides used to form the example jig 10. The figure shows that each of the sides 20 comprises a piece of sheet steel, wherein the lip 30 is part of the side that is folded over to form the lip 30. Further, the figure shows how the ends of each side comprise an aperture 40 suitable for receiving a fastening means such as a bolt.it is noted that the frame is configured by aligning the apertures 40 on the end of adjacent sides before inserting the fastening means through other of the overlapped sides to fasten them together in a way that allows the sides to pivot relative to each other, thereby allowing the frame to fold as described above. It can also be seen from these figures, that the ends of the sides 20 that comprise a lip 30 extend beyond the ends of the lip. These extended side ends allow the end of the adjacent sides to slide over each other without being obstructed by the lip 30. Note that one side 20D has extended ends on both sides, sides 20A and 20C have only one extended end, and side 20B does not have extended ends, as only one side of the fasted side needs the extended end to allow the sides to pivot. It is noted that different-shaped frames may similarly have sides with one or both ends extending beyond the lip 30. As previously noted, the frame may be supplied in different shapes or sizes compared to the depicted jig 10. In such cases, the jig may include additional size and / or comprises sides with different dimensions to those depicted. It is noted that these different sides would still comprise the features described above, such as the lip 30, fastening apertures 40, and extended sides. Further, regardless of the size and shape of the frame, it is still preferable to have the sides be made from metal as this would ensure that the frame is suitably strong to support the cement within the jig 10 and has little risk of wear or breaking after repeated uses. It is also noted that the frame is preferably formed from a chemically resistant metal, such as steel, as this prevents the frame sides 20 from reacting with the water and other compounds in the wet cement poured into the jig 10. It is also noted that some frames may further comprise a protective coating to further prevent the cement from reacting or sticking to the jig frame. It is also noted that the claimed frame may include adjustment features that allow the frame to be adjusted based on the user’s requirements. For example, the sides 20 of the frame may be configured to be extendable allowing the user to adjust the size of the frame to cover a larger area, in such cases, the sides of the frame may include telescopic sides, ratchet mechanisms, or other suitable mechanisms to allow the sides of the frame to extend before locking into place. Wherein the mechanism should be configured to lock at one or more different sizes so that the frame remains ridged when in use. In some cases, the lip 30 may be adjustable such that the lip may be removably attached to the frame side, and / or the height of the lip 30 may be adjusted relative to the frame side. As previously noted, it may be necessary for the lip 30 to rest at a height higher than the cement base the frame forms, for example when the lip rests on an adjacent tile or a surface higher than the cement base. Therefore, the lip may couple to the side via a suitable mechanism so that the lip height can be adjusted as necessary. Further, in some cases, the frame may need to be placed against a wall or another surface that the lip 30 cannot rest upon. In such cases, it would be preferable that the lip 30 be removable so that the lip 30 does not obstruct the positioning of the jig 10. In some cases, the base of the lip 30 may include a hinge so that when not in use the lip 30 can be rotated so that the lip is parallel to the attached side 20, or the lip may be rotated further so that the lip faces inwards instead of outwards. In either case, the rotation of the lip 30 help removes the lip 30 when it is obstructing the positioning of the jig 10. Figure 5 depicts an example profile for a side 20 of the jig 10, which includes the lip 30. In this case the side 20 has a L-shaped profile as depicted in the previous figures, with the addition of the S-shaped protrusion placed onto the top surface of the side 20, such that the lip 30 extends in the outward direction and the horizontal portion of the side 20 extends inwards relative to the walls of the jig 10. As previously noted, the inward protrusion provides a limit to the height of the cement base formed within the jig 10 as the user can level the cement with the height of the inward protrusion. Whereas the outward protrusion extending from the lip 30, may be used to limit the height of the jig 10 when it is placed in the area to be tiled. More specifically, the outward protrusion would be placed onto an adjacent tile or surface that the tiled area needs to be level with, with the outward protrusion latching onto this surface to keep the jig 10 at the height necessary to keep the tiled area level with the surrounding surface, and to ensure the tiles placed within the tiled area are level with each other. In the depicted example, the lip 30 is formed from a solid S-shape piece attached to the jig side 20, however, there are other possible designs, such as a L-shaped lip which mirrors the direction of the side L-shape profile. Further, in some cases, the lip 30 is not fixed and may be adjustable and / or removable. Wherein the adjustable lip may have its height relative to the jig 10 adjusted to adapt the jig 10 to tiles with different thicknesses. And in some cases, the lip 30 may be removable or adjustable horizontally. This allows the user to remove or effectively remove the lip 30 by moving the lip inwards or removing it from the side 20 entirely. This may be used in cases wherein the jig 10 is positioned next to a wall or a similar raised surface that would be taller than the tiled floor, as the lip 30 would not be able to latch onto such a surface, as such the lip 30 in these cases would only obstruct the positioning of the jig 10. Figure 6 shows how the side 20 from Figure 5 may be attached to an adjacent side of the jig 10. In this case, the horizontal surface of each side 20 has an aperture suitable for receiving a fastener. Wherein the user would align the apertures in the adjacent ends of two adjacent sides, this may be achieved by overlapping the ends of the sides 20 positioning the sides so such apertures on each side are aligned allowing a fastener to be passed through the aperture in both sides thereby fastening the sides together. It is noted that the fastener would be chosen such that the sides 20 can still pivot about the fastener, thereby allowing the frame to collapse as described above. In the case of the claimed invention, the term collapse refers to the sides of the jig frame folding such that the sides 20A-D lie parallel relative to each other. It is noted that the L-shaped profile depicted in the examples helps to achieve this as the hollow area formed by the vertical and horizontal portion of the side 20 may receive the adjacent side when the frame is folded. Note that in the depicted example the lip 30 does not cover the entire surface of the L-shaped side, thereby leaving space for the adjacent side to be received if it is placed over the side 20 which comprises the lip 30. Figures 7a, 7b, 7c, and 8 depict an example of a user using the claimed jig 10. In Figures 7a, 7b, and 7c, we can see the user unfolding a collapsed jig 10 to form a hollow frame suitable for receiving cement to form the cement base, note that in Figure 7a the frame is completely collapsed as the profile of the frame sides is configured to allow the frame to fold flat as illustrated in the previous figures. Figure 7b depicts how the folded frame can be easily unfolded by pulling apart the opposing sides of the collapsed frame thereby pivoting the joints in the frame to allow the frame to unfold. Figure 7c depicts the jig once the frame is fully unfolded, with the walls of the frame forming a hollow frame in the desired shape of the cement base, it is noted that the depicted examples present a rectangular frame of a particular size. However, it is noted that some frames may comprise telescopic or otherwise extendable sides to allow the user to adjust the size of the frame. Further, the frame may take different shapes depending on the user’s requirements. Figure 8 depicts an example of how the jig 10 can be used once the frame is unfolded. In particular, the frame is being placed over a section of the area to be tiled allowing the user to create a cement base by pouring cement into the placed frame. Note that the outward protrusions on the sides of the frame can be used to set the height of the cement base, and ensures that the tiles placed over the bases are level. This is because the protrusion would rest on the adjacent cement base or adjacent tiles depending on the height of the protrusion. It is noted that in some cases the protrusions may be adjustable and / or removable this allows the user to adjust the frame for different-sized tiles and may remove the protrusion when there is a surface like a wall that would otherwise obstruct the positioning of the jig 10. Lastly, it is noted that the present invention may be provided as a kit of parts that include a plurality of sides 20A-D configured to form the frame of the jig 10, where the sides may include lips 30 or the kit may include removable lips configured to be coupled to the sides, and a plurality of fastening means such as bolts suitable for coupling the sides of the kit together. Further, the kit may include a suitable tool for leveling the cement that is poured into the jig 10. The kit may further comprise a mallet that may be used to press the tile to be laid onto the surface of the cement base formed with the jig 10. By using the jig 10 as described above the user can ensure that the cement laid in a desired area is level across all the entire area, and can therefore ensure that the tiles placed onto the cement bases are level across the tiled area too. Thereby reducing the risk of tiles breaking or personnel falling when people walk over the desired area. 5 the jig 10 also allows the user to lay cement in the desired area in sections allowing the user to move within the desired area while working without having to step onto the wet cement base, thereby reducing the risk of the cement base being disturbed once it has been laid, reducing the risk of the cement needing to be re-leveled.

Claims

1. A jig (10) configured for forming a cement base, wherein the jig comprises; frame comprising;A plurality of walls (20A,20B,20C 20D) connected to form a hollow loop, wherein each of the walls has the same height equal to the desired thickness of the cement base;A lip (30) that extends from the first edge of one or more walls of the frame wherein the lip extends outwards towards the center of the frame.

2. The jig of claim 1, wherein one or more walls (20) comprise a lip that extends inwards from the first edge of the wall.

3. The jug of claims 1 and 2, wherein the outward lip (30) extends vertically from the wall such that the outward lip (30) is positioned above the first edge of the frame wall.

4. The jig of any preceding claim wherein the height of the inward and outward lips are adjustable.

5. The jig of claim 4 wherein the lips include ratcheted rails to adjust the lip height.

6. The jig of any preceding claim, wherein the one or more outward lips (30) are removable.

7. The jig of any preceding claim, wherein one or more walls (20) of the frame are configured to be extendable along the elongated axis of the wall.

8. The jig of claim 6 wherein the extendable walls include at least one of telescopic wall, sliding rails, or ratcheted rails to allow the wall to extend.

9. The jig of any preceding claim wherein at least one wall (20) of the frame includes a hinge or pivoting point such that the frame is collapsible.

10. The jig of claim 8, wherein each corner of the frame comprises a hinge or pivoting point.

11. A kit of parts comprising the jig of claims 1 to 9, and a tool configured to level the cement within the jig frame.

12. The kit of claim 10 wherein the leveling tool comprises a trowel or a float.

13. The kit of claims 10 and 11, wherein the kit further comprises a mallet.

14. The kit of any preceding claim further comprises a plurality of tiles with sides with lengths equal to the length of the sides of the frame.

15. A method of using the jig of claims 1 to 9, comprising the steps of:laying the frame over the desired area to be tiled;filling the frame with cement;using a suitable tool to level the cement within the frame, at a height equal to the height of the inward lip, by scraping the tool over the surface of the cement and the surrounding frame;removing the frame from the edge of the formed cement base.

16. The method of claim 15, further comprises the step of resting the outward lips on a cement base, tile, or floor adjacent to the desired area when laying the frame.

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