Patent Application
20130074425
Not Applicable
Not Applicable
1. Field of Invention
The present general inventive concept relates to tiles, slabs, or the like (hereinafter “tiles”). More particularly, the present general inventive concept pertains to a spacer for aligning and leveling adjacent tiles to assist in laying the tiles onto floors, walls, countertops, or the like.
2. Description of the Related Art
The use of tiles to form decorative and functional tile surfaces on floors, walls, countertops, and the like (hereinafter “surfaces”) is known in the art. In typical tile installation, a substrate layer of adhesive, such as mortar, cement, epoxy, or other adhesive (hereinafter “substrate”) is applied to a working surface. Tiles are overlaid along the substrate layer, often in a spaced-apart configuration to define a mortar joint therebetween. The mortar joint is filled with additional adhesive material, and the adhesive material forming the substrate layer and the mortar joint is allowed to set, thereby adhering the edges of the tiles to one another and to the working surface to form a finished tile surface. In laying and installing tiles in this manner, it is frequently desirable to establish a tile surface in which the exposed top surfaces of the tiles are aligned in a substantially co-planar relationship, and with mortar joints of equal width, so as to establish a generally uniform and planar tile surface. For the purposes used herein, it will be understood that the terms “planar” and “co-planar” refer to a surface which is reasonably flat, but which allows for contour variations in the surface of each tile and the depth of the mortar joints between adjacent tiles.
Proper alignment of adjacent tiles along a working surface during installation is often a time-consuming and labor-intensive process, but is nonetheless important for a number of reasons. For example, if one tile in an array of tiles forming a tile surface is misaligned in a direction along the working surface, the width of the mortar joints between the misaligned tile and adjacent tiles is often not uniform, the end result often being an unattractive and undesirable tile surface. If one tile in an array of tiles forming a surface is misaligned in a direction normal to the working surface, the end result is often an unacceptably non-planar tile surface. Furthermore, in the event a single tile in an array of tiles forming a tile surface is misaligned during installation of a tile surface, the misalignment is often carried on to subsequent adjacent tiles, thereby increasing the visibility of the misalignment in the tile surface.
The operation of laying, aligning, and leveling tiles is often difficult due, in part, to uneven working surfaces underlying the tile, such as for example, bowed or sagging floor surfaces. In such cases, it is often difficult to establish a co-planar relationship of the top surfaces of the tiles, in part due to the tendency of the substrate layer (and subsequently, the tiles overlaid thereon) to follow the contour established in the initial surface. Furthermore, it is not uncommon for tiles to shift or sink into the substrate layer as the adhesive sets. It is therefore often necessary to monitor newly installed tiles as the adhesive sets in order to ensure that the relationship of the top surfaces of the tiles remains within acceptable tolerances of co-planar. In the event a tile becomes misaligned during setting of the adhesive, it is often difficult to realign the tile without disturbing adjacent tiles.
Tile installers have used a variety of apparatus and methods in an attempt to maintain proper alignment of tiles during installation. A commonly used tool for positioning tiles is a tile rack, an example of which is illustrated in U.S. Pat. No. 3,775,856 (“the '856 patent”). The device of the '856 patent includes a grid forming a template for holding and positioning a number of floor tiles in respective grid sections. The device includes legs for supporting the grid above a working surface to allow sufficient space for the substrate layer. Use of the device of the '856 patent is itself a difficult task in that the grid is heavy and requires repeated moving and positioning adjustments as the tile installation operation progresses. Moreover, such tile racks are expensive, and their use is time consuming, requiring different sizes and patterning according to the tiles being laid. Thus, multiple tile racks are often required for a single tile installation, depending upon the size, shape, and patterns of tile to be installed.
In light of the above, it is desirable to provide an efficient and inexpensive spacer for laying tile which allows for leveling and alignment of tiles relative to each other during installation and which facilitates the installation of different sizes and patterns of floor tiles.
The present general inventive concept provides a spacer for laying tile which is useful, for example, in establishing a desired spacing and alignment between at least two adjacent tiles and between the tiles and a working surface. In one embodiment, the spacer comprises a substantially planar base plate sized to extend between the working surface and an interface of adjacent sides of at least two adjacent tiles to establish a space between the tiles and the working surface for receipt of a substrate layer therein. In one embodiment, the base plate has a thickness corresponding to a desired thickness of a substrate layer to be formed between the tiles and the working surface.
In several embodiments, the spacer further includes at least one fastener adapted to secure the base plate to the working surface. For example, in certain embodiments, the fastener is an adhesive layer. In another embodiments, a through bore is defined extending normal to the planar dimension of the base plate between the first surface and an opposite second surface of the base plate. In certain embodiments, the through bore defines a recess for receiving the fastener second portion between the first and second surfaces of the base plate. For example, in some embodiments, the recess is defined by an outwardly beveled surface of the through bore opening toward said first surface of said base plate. In certain embodiments, a fastener is provided having a first portion adapted to be received through said through bore and secured to the working surface and a second portion adapted to engage said base plate to secure said base plate along the working surface. In certain embodiments, the through bore is disposed at a central location along the base plate.
In some embodiments, the fastener is repositionable along the through bore to allow spacing of the base plate from the working surface. For example, in certain embodiments, a shim is provided which is receivable between the base plate and the working surface to bias the base plate toward engagement with the fastener second portion. In one embodiment, the shim is a rigid, tapered member. In another embodiment, the shim is a layer of resilient compressible material disposed along the base plate second surface.
A plurality of fins extends from a first surface of the base plate. Each fin is sized and configured along the base plate to extend between and abut adjacent sides of at least two adjacent tiles to establish a space between the tiles for receipt of a mortar joint therebetween. In one embodiment, the plurality of fins includes first and second fins disposed in a linear configuration on opposite sides of the through bore. In certain embodiments, each fin extends from an outer edge of the base plate toward a central location of the base plate. In certain embodiments, the plurality of fins includes first, second, third, and fourth fins, each the fin extending along the base plate first surface at right angles to two adjacent fins. In other embodiments, each fin extends from the base plate first surface a distance less than a thickness of the at least two adjacent tiles.
The present general inventive concept further provides a method of laying tile. In one embodiment of the method, a plurality of spacers are provided and arranged at locations along a working surface to establish a desired positioning and spacing of a plurality of tiles along the working surface to form a tile surface. The spacers are secured to the working surface at the arranged locations of the spacers. In an optional operation of the method invention, a desired separation distance between the working surface and each spacer is established to facilitate additional alignment and leveling of the tiles. A measure of suitable substrate material is placed between the base plates of the spacers. Each tile is positioned against the top surfaces the base plates of its associates spacers and in contact with the substrate layer, such that the spacers and the substrate layer cooperate to secure the tile to the working surface at the desired distance from the working surface. A measure of suitable mortar material is inserted in the spaces provided between the tiles to form the mortar joint between associated adjacent tiles. Thereafter, the substrate material and mortar material is allowed to set, thereby forming a finished tile surface.
The above-mentioned features of the invention will become more clearly understood from the following detailed description of the invention read together with the drawings in which:
A spacer for laying tile 10 is disclosed herein and in the various figures. The spacer for laying tile, or spacer 10, is adapted to be interposed between adjacent tiles 12 of a plurality of tiles 12 and between the plurality of tiles 12 and a working surface 14 over which the tiles 12 are laid to assist in aligning and leveling the plurality of tiles 12 relative to each other and relative to the working surface 14. In several embodiments, the spacer 10 is helpful in promoting a co-planar arrangement of spaced apart tiles 12 such that a space is provided between each tile 12 and the working surface 14 sufficient to accommodate a substrate layer 26 of a desired thickness between each tile 12 and the working surface 14, and such that even spaces are provided between adjacent tiles 12 for receipt of mortar joints 16 therein.
With initial reference to
In certain embodiments, the base plate 18 is configured to rest against the working surface 14, such that the separation between the working surface 14 and the tile 12 as provided by the spacer 10 is determined by the thickness of the base plate 18. As such, in certain embodiments, the base plate 18 is of a thickness approximating a desired minimum thickness of a substrate layer 26 to be provided between the tiles 12 and the working surface 14. For example, in one embodiment of the spacer 10 for use in establishing a substrate layer 26 having a thickness of approximately one-sixteenth ( 1/16) of an inch, the base plate 18 has a thickness of approximately one-sixteenth ( 1/16) of an inch. In this embodiment, upon placing the base plate 18 against the working surface 14 and between the working surface 14 and the adjacent edges 28 of the at least two adjacent tiles 12, the base plate 18 positions the tiles 12 at an offset distance between the tiles 12 and the working surface 14 of approximately one-sixteenth ( 1/16) of an inch, thus establishing a space between the tiles 12 and the working surface 14 sized to accommodate a substrate layer 26 between the tiles 12 and the working surface 14 of the same at least one-sixteenth ( 1/16) of an inch in thickness. Those skilled in the art will recognize that the thicknesses of the base plate 18 may vary in other embodiments depending on the desired separation of the tiles 12 from the working surface 14, and thus, the desired thickness of the substrate layer 26.
With reference to
Referring again to
In several embodiments, each through bore 32 defines a recess for receiving at least a portion of the head portion 40 of the fastener 34 therein. For example, in the illustrated embodiment, the through bore 32 defines an outwardly beveled surface 48 opening toward the top surface 20 of the base plate 18. The beveled surface 48 of the through bore 32 is dimensioned to allow a head portion 40 of a standard flat-head screw fastener 34 to be received and retained between the top and bottom surfaces 20, 22 of the base plate 18. Thus, upon engagement of the base plate 18 with the head portion 40 of the flat-head screw fastener 34, an upper surface of the head portion 40 is at least co-planar, and preferably slightly below, the top surface 20 of the base plate 18, such that the head portion 40 does not interfere with the tiles 12 contacting and bearing against the top surface 20 of the base plate 18.
In several of those embodiments discussed above which include at least one device to allow adjustment of the position of the base plate 18 in a direction normal to the working surface 14, at least one shim 44 is provided to establish separation of the base plate 18 from the working surface 14, and thereby to facilitate the adjustment of the position of the base plate 18 from the working surface 14. In several embodiments, each shim 44 is defined by a segment of substantially rigid material adapted to be at least partially inserted between the base plate 18 and the working surface 14 to provide space therebetween. For example, in the embodiment of
In certain embodiments, the expansion force exerted by the shim 44 is sufficient to maintain the desired separation distance between the base plate 18 and the working surface 14 following placement of the tiles 12 over the base plate 18. In other embodiments, following placement of the substrate layer 26 along the working surface 14 and placement of the tiles 12 in contact with the base plate 18 and substrate layer 26, the shim 44 cooperates with the substrate layer 26 to support the tile 12 and the base plate 18 at the desired separation distance from the working surface 14.
In certain more discreet embodiments, at least one adhesive layer 46 is provided between the working surface 14 and the remainder of the spacer 10 to further secure the base plate 18 against movement along the working surface 14. For example, in one embodiment, in which the separation of the base plate 18 from the working surface 14 is non-adjustable, an adhesive layer 46 is provided along the bottom surface 22 of the base plate 18 to secure the base plate 18 against the working surface 14. In another embodiment, such as the embodiment of
A plurality of fins 30 are provided along a top surface 20 of the base plate 18, with each fin 30 being adapted to be interposed between and abutted against at least two adjacent tiles 12 overlaying the base plate 18. Each fin 30 is of a width sufficient to establish a minimum desired spacing between the adjacent tiles 12, thereby allowing for placement of a mortar joint 16 between the adjacent tiles 12. In several embodiments, each fin 30 is generally rectangular shaped, having a length extending from an edge of the base plate 18 toward a central point of the base plate 18. However, it will be understood that the specific configuration of the fins 30 along the base plate 18 is dependent, at least in part, upon the desired pattern of tiles 12 to be overlaid along the base plate 18. For example, in the embodiment of
As discussed above, each fin 30 extends from the top surface 20 of the base plate 18 a distance sufficient to allow each fin 30 to be interposed between at least two adjacent tiles 12 to establish a space between the tiles 12 corresponding to a width of a desired mortar joint 16. In several embodiments, each fin 30 extends from the base plate 18 to a height below the desired height of the mortar joint 16 between the corresponding adjacent tiles 12. In these embodiments, upon placement of the spacer 10 between the tiles 12 and the working surface 14 with the fins 30 interposed between associated adjacent tiles 12 to define spaces between the tiles suitable for placement of a mortar joint 16, and upon placement of the substrate layer 26 between the working surface 14 and the tiles 12 as discussed above, suitable mortar may be inserted in the spaces provided between the tiles 12 to form the mortar joint 16 between the associated adjacent tiles 12. Upon placement of mortar between the tiles 12 to a depth sufficient to establish the desired height of the mortar joint 16, the fins 30 may be covered by the mortar joint 16, thereby concealing the entire spacer 10 beneath the tiles 12 and mortar joints 16 to establish a finished tile surface absent removal or reconfiguration of the spacer 10 beneath the tiles 12.
It will be understood by one of skill in the art that the spacer 10 as described above offers several unique advantages over the prior art. For example, it will be recognized that once the substrate layer 26 and mortar joints 16 are established surrounding a plurality of properly aligned adjacent tiles 12, movement of the tiles 12, substrate layer 26, or mortar joints 16 in relation to the working surface 14 is generally deleterious to the alignment of the tiles 12. To this extent, a plurality of spacers 10 may be positioned and secured along the working surface 14 as discussed above to establish the intended positioning and spacing of a series of adjacent tiles 12 to form a tile surface, and thereafter, the substrate layer 26 may be applied, the tiles 12 may be positioned against the substrate layer 26 and the spacers 10, and the spaces between adjacent tiles 12 may be filled to form the mortar joints 16, all without further reconfiguration, adjustment, or removal of the spacers 10. Similarly, once the spacers 10 are secured proximate the working surface 14, the substrate layer 26 is formed, and the tiles 12 are placed in proper alignment in contact with the substrate layer 26 and the spacers 10, the mortar joints 16 may be formed between the adjacent tiles 12 absent additional repositioning or removal of the tiles 12 from their position in proper alignment and in contact with the substrate layer 26 and the spacers 10.
A method of laying tile is further disclosed herein. In one embodiment of the method invention, a plurality of spacers 10 as described above are provided. The spacers 10 are arranged at locations along a working surface 14 to establish a desired positioning and spacing of a plurality of tiles 12 along the working surface 14 to form a tile surface. In certain embodiments, such arranging of the spacers is accomplished by first arranging both the tiles 12 and the spacers 10 along the working surface 14, with at least one spacer 10 extending beneath and between each two adjacent sides of the plurality of tiles 12, such that the spacers 10 establish. In one embodiment, the tiles 12 and spacers 10 are arranged along the working surface 14 with one spacer 10 extending beneath and between each intersection of four adjacent tiles 12. Thereafter, the tiles 12 are removed from the spacers 10 and the working surface 14, leaving the spacers 10 arranged at the above-discussed locations along the working surface 14.
The spacers 10 are secured to the working surface 14 at the arranged locations of the spacers 10. In an embodiment in which spacers 10 are provided having the above-discussed resilient shims 44, adhesive layers 46, through openings 32 and fasteners 34, each spacer 10 is adhered to the working surface 14 at the location of its arrangement along the working surface 14 by the adhesive layer 46. A fastener 34 is inserted through each through opening 32 in each base plate 18 of the spacers 10 and driven into the working surface 14, thereby further securing the spacer 10 to the working surface 14.
In an optional operation of the method invention, a desired separation distance between the working surface 14 and each spacer 10 is established to facilitate additional alignment and leveling of the tiles 12. For example, in several embodiments, the depth of penetration of each fastener 34 into the working surface 14 is adjusted to position each head portion 40 of each fastener 34 at a distance from the working surface 14 such that each head portion 40 restrains separation of an associated spacer 10 from the working surface 14 to within the desired separation distance. In one embodiment in which a resilient shim 44 is provided, each resilient shim 44 is compressed during adjustment of the depth of penetration of its associated fastener 34. Thus, each resilient shim 44 is allowed to exert an expansion force to separate its associated spacer 10 from the working surface 14 to establish engagement between the spacer 10 and the head portion 40 of the fastener 34, thereby positioning the spacer 10 at the separation distance from the working surface 14. In another embodiment, in which at least one rigid shim is provided, the shim is inserted between the spacer 10 and the working surface 14 to separate the spacer 10 from the working surface 14 to establish engagement between the spacer 10 and the head portion 40 of the fastener 34, thereby positioning the spacer 10 at the separation distance from the working surface 14.
A measure of suitable substrate material is placed between the base plates 18 of the spacers 10. Each tile 12 is then positioned against the top surfaces 20 the base plates 18 of its associates spacers 10 and in contact with the substrate layer 26, such that the spacers 10 and the substrate layer 26 cooperate to secure the tile 12 to the working surface 14 at the desired distance from the working surface 14. A measure of suitable mortar material is inserted in the spaces provided between the tiles 12 to form the mortar joint 16 between associated adjacent tiles 12. In one embodiment, the mortar material is inserted to a depth between the tiles 12 sufficient to cover the fins 30 of each of the spacers 10. Thereafter, the substrate material and mortar material is allowed to set, thereby forming a finished tile surface.
While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.
