This invention relates, in general, to tile installation and, in particular, to a system and device for leveling and aligning tiles and properly spacing tiles during the installation thereof.
Tile has become a popular decorative and functional article for use in floors, walls, countertops, and the like. Both professional tile installers and do-it-yourselfers spend a great deal of time aligning and leveling tiles as they are being placed on a substrate's surface. Proper alignment and leveling of each tile is important for a number of reasons. Improper installation can cause the need for tiles to be replaced in order to prevent a spacing error from propagating across the substrate, aesthetic reasons, and in some instances, safety concerns. A need exists for a device for leveling and aligning tiles and properly spacing tiles.
It would be advantageous to achieve a device for leveling and aligning tiles and properly spacing tiles. It would also be desirable to enable a mechanical-based solution that furnishes an inexpensive tool that assists professional tile installers and do-it-yourselfers. To better address one or more of these concerns, in one aspect of the invention, a system and device for leveling and aligning tiles and a method for leveling and aligning tiles are disclosed. In one embodiment of the tile leveling system, a tile leveling device includes an upright body having a head and base at opposite ends thereof. The base and the upright body are integral prior to a frangible separation. The tile leveling device is selectively threaded through a line-of-sight opening of a wedge device for use in an operational configuration. These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
Referring initially to
In some embodiments, the tile leveling device may also include a spacer 46 extending from the front 24 of the upright body 18. The spacer 46 is configured to position a tile at a predetermined distance from the tile leveling device 14. Similarly, the tile leveling device 14 may include a spacer 48 extending from the rear 26 of the upright body 18 in order to position a tile at a predetermined distance. It should be appreciated that the spacers 46, 48 may act as spacing pads that are integral with the upright body 18 and may vary in thickness depending on the application. The spacers 46, 48 contribute to furnishing a combination of vertical leveling and joint spacing within a single product.
In some embodiments, the tile leveling device 14 includes respective clipped corners 50, 52 at an intersection of the head 32 and the guide surface 34, which may be transverse, with clipped corner 50 being positioned at the left guide surface portion 36 and the clipped corner 52 being positioned at the right guide surface portion 38. The clipped corners 50, 52 improve and provide clearance between the head 32 and the wedge device 16 during the interconnection of the tile leveling device 14 and the wedge device 16, to better accommodate multiple tile thicknesses and keep the entire assembly as compact as possible. The tile leveling device 14 may also include a flared portion 54 proximate the lower end 22 of the upright body 18. In some embodiments, the flared portion 54 provides greater strength to the upright body 18 while spreading the tension during operation across a frangible breakaway section 94. The flared portion 54 may have a triangular appearance with a tapered edge. In this manner, the flared portion 54 provides additional strength while having a form factor which does not interfere with the selective interconnectivity of the tile leveling device 14 and the wedge device 16. The combination of the additional strength and increased spread of tension provides sufficient support as tiles are manipulated through the installation process. Further, this combination of the additional strength and increase spread of tension provides sufficient support for manipulating tiles of different thicknesses during the tile installation process.
As shown, in the illustrated embodiment, a base 60 is orthogonally coupled to the lower end 22 of the upright body 18. The base 60 includes an upper surface 62 and a lower surface 64 extending from a midline 66 of the base 60 to the front 24 of the upright body 18 and the rear 26 of the upright body 18. The upper surface 62 and the lower surface 64 intersect at a front edge 68, which is positioned at the front 24 of the upright body 18. Similarly, the upper surface 62 and the lower surface 64 intersect at a rear edge 70, which is positioned at the rear 26 of the upright body 18.
As shown, the base 60 includes a thickness T1 greater at the midline 66 than a thickness T2 at the front edge 68 or a thickness T3 at the rear edge 70, providing, in some embodiments, a sharp insertion point. In one embodiment, the variation in thickness arises from the upper surface 62 being a substantially horizontal surface and the lower surface 64 being a non-linear surface that is tapered from the midline 66 toward each of the front edge 68 and the rear edge 70. With this arrangement, each of the front edge 68 and the rear edge 70 provide an entry wedge, such as an entry wedge 72 and an entry wedge 74, sized for easier insertion between a tile and subsurface.
The base 60 may have any shape, including circular shapes, rectangular shapes, triangular shapes, or typographical shapes, like the letter “H” or “I.” In one embodiment, the base 60 is an I-shaped base. Spaced and parallel strip members 76, 78 provide four points of contact 80, 82, 84, 86 for lift of tiles, while still establishing space for maximum mortar penetration between the spaced and parallel strip members 76, 78. Further, it should be appreciated that the base 60 may include base elements such as holes, openings, notches, grooves, and combinations thereof, for example. As shown, in one embodiment, the base 60 includes notches 88, 90.
In some embodiments, a base-to-body coupling 92 positioned at the intersection of the upright body 18 and the base 60 includes the frangible breakaway section 94. The upright body 18 and the base 60 are integral prior to frangible separation such that the frangible breakaway section 94, upon breaking, frangibly separates the upright body 18 and the base 60. The frangible breakaway section 94 may be a frangible section of the upright body 18 of reduced thickness that would promote the breakaway, and thus, separation of the upright body 18. The frangible breakaway section 94 may include one or more frangible breakaway section portions and may include features like small holes, tapered edges, and the like. By way of example, the base 60 may include a channel 96 at the base-to-body coupling 92. The channel 96 lowers the breakoff point at or below a top of the base 60.
In some embodiments, the wedge device 16 includes a backstop member 100 and a body member 102. As shown, the body member 102 may have an attachment end 104, a penetrating edge 106, a top 108, a bottom 110, and sidewalls 109, 111. The attachment end 104 is coupled to the backstop member 100 and the penetration edge 106 may be configured to penetrate the tile leveling device 14 at the guide surface 34. The body member 102 may include an inclined plane 112 tapering from the attachment end 104 to the penetrating edge 106. The body member 102 includes a longitudinal axis 114 from the attachment edge 104 to the penetrating edge 106. As depicted, the longitudinal axis 114 has a longitudinal length L1.
A line-of-sight opening 116 extends along the longitudinal axis 114 and intersects the longitudinal length L1 with the line-of-sight opening 116 having an opening length L2 and an opening width W2. The line of sight opening 116 is configured to be penetrated by the tile leveling device 14. In one implementation, the opening length L2 is greater than the head width W1 and the opening width W2 is greater than the head depth D1. In this manner, the opening width W2 accommodates the perimeter 28 to permit rotational movement of the upright body 18 of the tile leveling device 14 within the line-of-sight opening 116. With this configuration, the tile leveling device 14 and the wedge device 16 may be interconnected by insertion then rotation, as shown by arrows AI, AR. The line-of-sight opening 116 also provides visibility through the body member 102 from the top 108 to the bottom 110. The inclined plane 112 may include a toothed surface 118. In operation, teeth forming the toothed surface 118 prevent the wedge device 16 from slipping out of contact with the left guide surface portion 36 and the right guide surface portion 38 forming the guide surface 34 during penetration thereof. As will be appreciated, the wedge device 16 may penetrate the tile leveling device 14 from the front 24 or rear 26.
In one embodiment, the body member 102 of the wedge device 16 includes a beveled edge 120 at an intersection of the bottom 110 and the line-of-sight opening 116. The beveled edge 120 and the flared portion 54 work with the clipped corners 50, 52, providing greater strength while accommodating multiple tile thicknesses as it allows the lower end 22 of the upright body 18 of the tile leveling device 14 to start at a higher point and disperse the applied pressure. In particular, the clipped corners 50, 52 improve and provide clearance between the head 32 and the beveled edge 120 when the tile leveling device 14 is selectively threaded through the line-of-sight opening 116 of the wedge device 16 as will be discussed in further detail hereinbelow. Further, as shown, the body member 102 at the penetrating edge 106 includes a closed end member 122 forming a closed loop 124 that provides a slotted wedge design. When the penetrating edge 106 fully engages the tile leveling device 14, the closed end member 122 interconnects inclined plane members 126, 128 of the inclined plane 112 to strengthen side-to-side placement of tiles by ensuring more uniformed distribution of forces of the tiles and ensuring that the inclined plane members 126, 128 are in the same vertical plane. For additional support, a base extension member 130 circumscribes the sidewalls 109, 111 and the backstop member 100. The base extension member 130 may also ensure more uniform distribution of forces on the tiles and ensure the inclined plane members 126, 128 stay within the same vertical plane, particularly in instances where three or four tiles are being installed. It should be appreciated that although a particular wedge device, the wedge device 16, is shown, the tile leveling system, including the tile leveling device 14, may be utilized with other types of wedge devices. By way of example and not by way of limitation, the wedge device 16 may have an open end rather than a closed end member at the penetrating edge, as will be presented below. In the open end embodiments, in some implementations, the open end defines a double headed wedge.
Referring now to
Referring now to
Referring now to
As shown, the tile TL1 is over the base 60 to the front 24 of the upright body 18. As mentioned, the tile TL1 has a lower surface opposite an upper surface. The tile TL1 has contact with mortar M at the notch 88 (as best shown in
In operation, an individual may place the tile leveling system 10, including the tile leveling device 14, on the subsurface S and then position the mortar M and desired number of tiles. As best seen in
Referring now to
As previously discussed, mechanical tile leveling systems have become increasingly popular. The tile leveling system 10 presented herein provides speed of operation through a simple system. Additionally, the present tile leveling system 10 decreases waste by providing a less wasteful, more compact solution. It is normal for thousands of clips to be used during a single tile installation job and as the tile leveling device 14 is intentionally divided in half at the base-to-body coupling 92, waste is created, including the upright body 18 and the head 32, for example. Compared to other tile leveling systems, the upright body 18 and the head 32 represent a reduction in the amount of waste as the upright 18 and the head 32 require approximately 75% less plastic than other mechanical tile leveling systems 10. Importantly, however, the reduced plastic does not compromise strength due to the design of the tile leveling device 14, including the upright body 18 interposed between the head 32 and the flared portion 54 that provide a wide bottom portion, strong pole portion, and wide top portion.
The order of execution or performance of the methods and techniques illustrated and described herein is not essential, unless otherwise specified. That is, elements of the methods and techniques may be performed in any order, unless otherwise specified, and that the methods may include more or less elements than those disclosed herein. For example, it is contemplated that executing or performing a particular element before, contemporaneously with, or after another element are all possible sequences of execution.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
This application claims priority from U.S. Patent Application Ser. No. 63/147,554 entitled “System and Device for Leveling and Aligning Tiles and Method for Use of Same” filed on Feb. 9, 2021, in the names of Clinton D. Bunch et al.; which is hereby incorporated by reference, in entirety, for all purposes.
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