Patent Application
20200284052
This disclosure generally relates to tile laying and, in particular, a method and device for cutting custom-sized tiles for installation adjacent an angled vertical surface.
Laying floor tiles is a time consuming task, but also one requiring precise measurement and close attention to detail. When laying tile in a room, a worker typically begins by laying (i.e., installing) uncut tiles in the central areas of the room. At the peripheries of the room, however, an uncut tile is most likely too large to exactly fit within the space left between adjacent uncut tiles and a wall or other vertical surface. What's more, a wall may be at an irregular angle with respect to the laid tiles. For example, a wall may be oriented at an angle such that no side of a square or rectangular tile would be parallel to the wall if the tile were installed. The irregular angle of a wall may be an intentional aspect of the room's design or an unintended consequence of hurried construction or shifts in a building's structure.
To adjust for the irregular angle of the wall, a worker typically attempts to cut a custom tile such that the appropriate side of the tile is angled to match the angle of the wall once the tile is installed. Producing the custom tile may often involve taking measurements at various intervals between the wall and the back edge of the tile. These measurements are generally taken with a measuring tape and thus are subject to the potential imprecisions and inaccuracies involved in their use. Further, creating a custom tile may degrade into a time consuming trial-and-error process in which a worker initially takes measurements and writes them down, moves to a tile cutting station, cuts the tile according to the measurements, and moves back to the tile placement location. In many cases, the cut tile does not fit as expected. The worker must then take the tile back to the cutting station, further cut the tile (or start over on a new tile), and repeat the process until the tile has the proper dimensions and angles for the placement.
At times, floor tiles may be installed in a room with baseboards at the junction of the floor and walls. In this case, some imprecision may be tolerated since the baseboard typically is installed on top of the edges of the tile. The above-noted difficulties, however, are compounded when a project requires that grout be installed between the outer tiles and the wall or other vertical surface. For example, the floor tiles in a bathroom are often expected to nearly abut against the vertical surface of wall tiles, with grout or other sealant being installed therebetween to create a water-tight seal. In this case, any misalignment of the edge of the tile to the wall is plainly evident and creates a poor visual impression.
These and other shortcomings are addressed in the present disclosure.
Disclosed herein are a device for use in creating a custom tile to be installed in an irregular space adjacent an angled wall or other vertical surface. An example device includes an elongated first member and an elongated second member that is pivotally connected to the first member via a hinge. The hinge is configured to selectively prevent or enable pivoting of the first member and the second member at the hinge. The device includes a slide piece that is slidingly coupled to the first member. The slide piece is configured to selectively prevent or enable movement of the slide piece lengthwise along the first member. The slide piece comprises a body. The body comprises a longitudinal alignment element that extends parallel to the longitudinal axis of the body. The body further comprises a lateral alignment element arranged perpendicular to the longitudinal alignment element. The longitudinal alignment element and the lateral alignment element together define a recess at a bottom portion of the body. The recess is configured to receive a corner of a tile. The body further comprises a spacer configured to selectively extend from or retract into the body. The spacer comprising a second lateral alignment element that is parallel to the first lateral alignment element of the body. The first lateral alignment element of the body and the second lateral alignment element of the spacer define a space therebetween when the spacer is at least partially extended from the body.
Said device may be used in an example method to determine a cut angle and a cut dimension for an uncut custom tile that is to be installed between an installed tile and a fixed vertical surface oriented at an irregular angle with respect to the installed tile. The example method includes positioning the second member to abut the fixed vertical surface. The first member is positioned parallel to a side edge of the installed tile. While the second member abuts the fixed vertical surface and the first member is parallel to the side edge of the installed tile, the hinge is operated to prevent the first member and the second member from pivoting relative to one another. An angle between the first member and the second member comprises the cut angle. Further while the second member abuts the fixed vertical surface and the first member is parallel to the side edge of the installed tile, the device and the slide piece are positioned such that a corner of the installed tile, defined in part by the side edge of the installed tile, occupies the first recess and abuts both the first longitudinal alignment element of the body and the first lateral alignment element of the body. The cut dimension for the custom tile comprises a distance between the second lateral alignment element of the spacer and a distal end of the first member at the hinge.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments and together with the description, serve to explain the principles of the methods and systems:
Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.
The present disclosure relates to a device configured to aid in laying floor tile or other similar material, such as linoleum squares or even wall or ceiling coverings. The present disclosure further relates to methods of using said device to lay tile. As examples, the disclosed device facilitates measuring one or more tile dimensions useful for installing a tile abutting a vertical surface, such as a wall, in particular a wall positioned at an irregular angle (e.g., not horizontally perpendicular) relative to the orientation of tiles already installed within the space. The disclosed device further facilitates determining one or more angles according to which a custom tile is preferably cut for installation at the angled vertical surface. Additionally, the disclosed device facilitates cutting tile according to the determined one or more cut dimensions and one or more cut angles.
Reference is made herein to the attached drawings. Like reference numerals throughout the drawings shall refer to same or similar components or features unless clearly indicated otherwise by express statement or context.
The first member 12 is configured with a slide piece 18 that is selectively movable lengthwise along the first member 12 (i.e., along the longitudinal axis of the first member 12). As will be described further herein, the slide piece 18 is configured with a hollow through which the first member 12 passes. The hollow of the slide piece 18 is sized so that the first member 12 is generally free from movement or “play” within the slide piece 18 except for the lengthwise movement of the slide piece 18 along the first member 12. The slide piece 18 is configured to selectively limit or prevent its movement along the first member 12. For example, the position of the slide piece 18 on the first member 12 may be frozen, in conjunction with the angular position of the first member 12 and the second member 14 also being frozen, as part of the disclosed tile preparation process.
The first member 12 and the second member 14 are inscribed as rulers, but, as the disclosure will make clear, such ruler inscriptions are not necessary for effective use of the device 10. Indeed, the device 10 and disclosed methods of use largely do away with the need for a ruler or other measuring device while cutting custom-fitted edge tiles. The first member 12 is configured with a greater length than the second member 14, but the disclosure is not so limited. The slide piece 18 may be removed from (e.g., slid off of) the first member 12 and slid onto the second member 14 to better accommodate various tile/wall configurations and workspaces. The second member 14 is generally sized so as to at least span the width of a tile while marking a cutline on the tile. By doing so, the operator need only make a single swipe or motion with a pencil or the like to mark the cutline. The first member 12 and the second member 14, and indeed the device 10 as a whole, may be sized according to contemplated uses. For example, a bathroom installation may use smaller tiles than those used in a commercial space installation, and the device 10 may be sized accordingly.
As best seen in
The slide piece 18 also comprises an adjustable spacer 26. The spacer 26 is configured with an opening 28 through which the first member 12 also passes. The spacer 26 may be positioned relative to the body 19 by an operator such that the dimensions of a cut tile includes an offset that allows for space for grouting between the cut tile and a vertical wall and/or between the cut tile and an adjacent installed tile. A space 27 is defined between the spacer 26 and the opposite portion of the body 19 of the slide piece 18.
A portion of the spacer 26 extends into the hollow 24 of the body 19 of the slide piece 18. An operator may define or adjust the particular grouting offset afforded by the spacer 26 by further extending the spacer 26 from the hollow 24 of the body 19 of the slide piece 18 or retracting the spacer 26 into the hollow 24 of the body 19 of the slide piece 18. The spacer 26 may be configured with a stop 29 to limit the retraction of the spacer 26 into the body 19, as well as provide a protrusion that an operator may manipulate for extension or retraction of the spacer 26. Extension or retraction of the spacer 26 is selectively restricted or enabled by manual manipulation of a spacer lock 30. The spacer lock 30 may comprise a thumbscrew installed within a threaded bore in the top portion of the body 19 of the slide piece 18. When tightened, the thumbscrew presses against the portion of the spacer 26 within the hollow 24 of the body 19 of the slide piece 18, thereby restricting movement of the spacer 26. With sufficient manipulation of the thumbscrew, the spacer 26 may be locked in place. Conversely, the thumbscrew may be loosened to again allow for the spacer 26 to be extended or retracted with respect to the hollow 24 of the body 19 of the slide piece 18. The spacer lock 30 may be laterally offset from the longitudinal axis of the slide piece 18, such as to account for a lengthwise slot going down the middle (widthwise) of the first member 12.
The spacer 26 further comprises a depressed channel 32 aligned with the longitudinal axis of the slide piece 18. The channel 32 may be laterally centered with respect to the width of the spacer 26. The channel 32 defines a longitudinal slot 33 positioned to accommodate the screw portion of the slide piece lock 22. The channel 32 and the slot 33 may correspond with the position of a longitudinal alignment element 38 (discussed below) on the bottom portion of the body 19. In particular, the internal sides of the channel 32 and/or slot 33 may correspond with the side surfaces of the longitudinal alignment element 38 such that the position of a side surfaces of the longitudinal alignment element 38 may be determined by reference to the corresponding internal side of the channel 32 and/or slot 33.
As shown in
Although not shown in
Additionally or alternatively, the rule markings 25 may be color-coded according to common industry standard grouting space widths. For example, an orange rule marking 25 may indicate a ¼ inch grouting space, a blue rule marking 25 may indicate a 3/16 inch grouting space, a white rule marking 25 may indicate a ⅛ inch grouting space, and a green rule marking 25 may indicate a 1/16 inch grouting space. In an embodiment, the rule markings 25 may be each double color-coded. One color coding of a rule marking 25 may indicate a width value for when the custom-cut tile is to be installed with a single grouting space and a second color-coding of the rule marking 25 may indicate a width value for when the custom-cut tile is to be installed with two opposite grouting spaces. A rule marking 25 may be labeled with two numerical width values in a similar fashion.
With particular attention to
The longitudinal alignment element 38 and the lateral alignment element 40 together define a first recess 34 and a second recess 36 opposite the first recess 34. In particular, and as best seen in
In a mirror arrangement to the longitudinal alignment element 38 and the lateral alignment element 40 of the body 19, the spacer 226 comprises a longitudinal alignment element 254 and a lateral alignment element 256. The longitudinal alignment element 254 and the lateral alignment element 256 of the spacer 226 are arranged in a T-formation, with the longitudinal alignment element 254 being perpendicular to the lateral alignment element 256. The longitudinal alignment element 254 extends along the central longitudinal axis of the slide piece 18 and aligns with the longitudinal alignment element 38 of the body 19. The sides of the longitudinal alignment element 254 and the sides of the longitudinal alignment element 38 likewise align, respectively. The first inner surface 38a of the longitudinal alignment element 38 (partially defining the first recess 34 in the body 19) longitudinally aligns with a first inner surface 254a of the longitudinal alignment element 254 of the spacer 226. Similarly, the second inner surface 38b of the longitudinal alignment element 38 (partially defining the second recess 36 in the body 19) longitudinally aligns with a second inner surface 254b of the longitudinal alignment element 254 of the spacer 226. Thus, the lateral widths of the longitudinal alignment element 38 of the body 19 and the longitudinal alignment element 254 of the spacer 226 may be equal. The lateral alignment element 40 of the body 19 and the lateral alignment element 256 of the spacer 226 are parallel to one another, with the space 27 being defined therebetween.
As noted, the first inner surface 254a of the longitudinal alignment element 254 and the first inner surface 256a of the lateral alignment element 256 define the first recess 250. The first recess 250 of the spacer 226 is configured to accept a corner of a tile, such as when positioning the device 10 at the uncut custom tile. The second inner surface 254b of the longitudinal alignment element 254 and the second inner surface 256b of the lateral alignment element 256 define the second recess 252, opposite the first recess 250. The second recess 252 is also configured to accept a corner of a tile, such as when positioning the device 10 at the uncut custom tile. A configuration having both the first recess 250 and the mirror second recess 252 provide additional flexibility in using the device 10 with either the left side or the right side of a tile. In an aspect, the spacer 226 may be a modification over the spacer 26 only insofar as the addition of the longitudinal alignment element 254, without the additional horizontal surfaces and the extension of the opening 28 shown in
The slot 260 in the first member 12 may be used to facilitate positioning the device 10 at the uncut custom tile, particularly with respect to aligning the edge of the uncut tile such that the edge aligns with the particular longitudinal inner surface (e.g., the first inner surface 38a or the second inner surface 38b) of the longitudinal alignment element 38 that was used in an initial step of determining the angle between the first member 12 and the second member 14. Since the widths of the slots 260 generally equal the width of the longitudinal alignment element 38 of the body 19, an operator may look through a slot 260 while positioning the device 10 at the uncut tile to determine that the edge of the uncut tile is flush with the edge of the slot 260. Yet it will be noted that, for purposes of illustration, the slots 260 are depicted as being slightly wider than and/or offset from the longitudinal alignment element 38 of the body 19 and longitudinal alignment element 254 of the spacer 226.
The tile is to be cut to leave equal grouting spaces, the distances d1, between the cut tile and the installed tile 62 and between the cut tile and the wall 60. The spacer 226 may be configured (e.g., extended and/or retracted) for a distance d2 between a surface of the lateral alignment element 40 (facing the space 27) and a surface of the lateral alignment element 256 of the spacer 226 facing away from the space 27 and toward the hinge 16 (e.g., the first inner surface 256a or the second inner surface 256b of the lateral alignment element 256). The distance d2 may be twice the distance d1, such as when grouting is to be installed both between the cut tile and the adjacent angled wall 60 and between the cut tile and the adjacent installed tile. Alternatively, the distance d2 may equal the distance d1, such as when no grouting is to be installed between the cut tile and the adjacent angled wall 60. An operator may use the rule markings 25 shown in
At the tile installation location, the wingnut 20 or other hinge tightener is loosened so that the first member 12 and the second member 14 are able to pivot freely upon manual manipulation. Likewise, the slide piece lock 22 or other movement restrictor is loosened so that the slide piece 18 is able to slide freely along the first member 12 upon manual manipulation. The slide piece 18 may be positioned along the first member 12 anywhere between the junction with the second member 14 and the installed tile 62, such as at position p1. The device 10 is held such that the top portion of the slide piece 18 comprising the slide piece lock 22 and the spacer lock 30 are facing upward. The longitudinal alignment element 38 and the lateral alignment element 40 on the bottom portion of the slide piece 18 are shown for reference by dotted lines. The longitudinal alignment element 254 and lateral alignment element 256 of the spacer 226 are likewise shown for reference by dotted lines.
The first member 12 and the second member 14 are pivoted so that the second member 14 is flush to the wall 60 and the first member 12 is parallel to the side edge of the installed tile 62. Once this positioning is established, the wingnut 20 may be tightened down until the first member 12 and the second member 14 are unable to pivot and are locked into their relative positions. The angle between the first member 12 and second member 14 should be maintained while the wingnut 20 is tightened. The angle between the first member 12 and second member 14 at this point may be considered the cut angle for the custom tile.
Next, the slide piece 18 is slid toward the installed tile 62 until, at position p2, the corner of the installed tile 62 occupies the first recess 34 and is flush with (i.e., abuts) both the lateral alignment element 40 and the longitudinal alignment element 38. That is, the slide piece 18 is positioned such that the top edge of the corner of the tile 62 is flush against the first inner surface 40a of the lateral alignment element 40 and the side edge of the corner of the tile 62 is flush against the first inner surface 38a of the longitudinal alignment element 38. This may involve some movement of the device 10 as a whole but the second member 14 should still be held flush with the wall 60 when the corner of the installed tile 62 is positioned in the first recess 34. While maintaining the position of the slide piece 18 and the device 10 in general, the slide piece lock 22 is to be tightened until the slide piece 18 is unable to move and the position of the slide piece 18 on the first member 12 is fixed.
The device 10 may be removed from the installed tile 62 and taken to a cutting station to cut the custom tile for installation. Neither the position of the slide piece 18 on the first member 12 nor the pivot angle of the first member 12 and the second member 14 should have been allowed to change in the meantime.
With reference to
More generally, the device 10 is positioned laterally such that the side of the tile 70 is aligned with the inner surface 38a of the longitudinal alignment element 38 that defines the first recess 34. Since the width and lateral positioning of the slots 260 in the first member 12 correspond with the longitudinal alignment element 38, an operator may use the slots 260 as a visual or tactile guide in laterally positioning the device 10. For example, the operator may position the device 10 so that the side edge of the tile 70 aligns with and is flush with the left side edge of the slot 260. With respect to the longitudinal position of the device 10 on the tile 70, the lateral alignment element 256 (and/or the spacer 26) may serve as a stop such that the correct longitudinal position of the device 10 is determined when the bottom of the tile 70 abuts the lateral alignment element 256 (and/or the spacer 26). It is again noted that the slots 260 are shown in
Additionally or alternatively, an operator may use the channel 32 (and/or slot 33) in the spacer 226 (or the spacer 26) as a point of reference in positioning the device 10 at the tile 70. This may be performed by aligning the side of the tile 70 with the corresponding side of the channel 32 (and/or slot 33). It will be recalled that an interior side of the channel 32 and/or slot 33 may correspond (e.g., align) with the respective side of the longitudinal alignment element 38. The interior sides of the channel 32 and/or slot 33 may be used as a visual or tactile point of reference for the sides of the longitudinal alignment element 38.
Once the device 10 and the tile 70 are secured in this position, a cutline 72 is made using the top straight edge (that was previously flush with the wall 60) of the second member 14. The top straight edge of the second member 14 may comprise the edge of the second member 14 distal from the bottom edge of the tile 70. The second member 14 may be sized such that the cutline 72 fully spans the tile 70. If the second member 14 is not of sufficient length, a partial cutline may be initially marked and then fully extended to create the complete cutline 72. The tile 70 may be cut along the cutline 72 to create the cut tile 74. The cut tile 74 may be installed in the anticipated space (indicated by the dotted line 64 in
It will be appreciated that the device 10 may be used on either side of the installed tile 62 by virtue of the first recess 34 and the opposite second recess 36 of the body 19 of the slide piece 18, as well as the first recess 250 and the second recess 252 of the spacer 226 if the device 10 is so configured. This may be advantageous when the position within the workspace of the installed tile 62 and/or cut tile 74 prevents use of the device 10 on one side of the tile. For example, that side of the tile may be adjacent a second wall. Rather than position the device 10 at the right side (from the perspective of
As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.
Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other components, integers or steps. “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal embodiment. “Such as” is not used in a restrictive sense, but for explanatory purposes.
It will be apparent to those skilled in the art that various modifications and variations may be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.
