Tiles are installed on surfaces such as floors, walls, countertops, and the like. Installers spend a significant amount of time aligning and leveling tiles as the tiles are being placed on an installation surface. Proper alignment and leveling of each tile is important, because if one tile is improperly installed, the error continues in adjacent tiles such that the installed tiles become aesthetically unacceptable, and the tiles need to be re-installed and/or replaced. Replacing or otherwise correcting errors in tile installation is both costly and time-consuming.
In particular, many installation surfaces have a relatively large size and/or defects and imperfections such as dips, ridges, curvatures, out-of-plane or uneven regions. In addition, tiles may be uneven in dimension or varying in size and thickness. Thus, the tiles, if not properly leveled or aligned, will be unevenly installed on the surface out of level or plane. The unleveled tiles installed on a floor surface may additionally cause safety problems. For example, people may trip or fall on the uneven tiles. There is thus a need for a versatile, low-cost, fast, and effective tool for leveling and aligning tiles to be installed on a surface.
In general terms, this disclosure is directed to tools, systems, and methods for arranging, and/or leveling, and/or aligning tiles. In one possible configuration and by non-limiting example, a tile leveling tool for guiding installation of tiles on an uneven installation surface is disclosed. Various aspects are described in this disclosure, which include, but are not limited to, the following aspects.
One aspect is a tile leveling tool for guiding installation of tiles on an uneven installation surface. In one embodiment, a tile leveling tool comprises an elongated main body extending along a longitudinal axis thereof, from a first end to a second end, wherein the main body further comprises a flat reference side, wherein the reference side has a straight reference edge parallel to the longitudinal axis; and at least one adjustable spacer extending from the main body configured to extend toward the installation surface, wherein the adjustable spacer is configured to adjust a space between the main body and the installation surface to arrange the reference edge straight across the uneven installation surface and to guide the installation of the tiles evenly.
Another aspect is the tile leveling tool, wherein the tile leveling tool further comprises one or more anchors configured to secure the tool on the uneven installation surface.
A further aspect is the tile leveling tool, wherein the tile leveling tool further comprises an interlocking element configured to removably connect the tool to another tool along the longitudinal axis, wherein the connected tools form a track that provides an extended reference side that is co-planar and an extended reference edge that is straight.
Yet another aspect is the tile leveling tool, wherein the main body of the tool has a substantially rectangular cuboid configuration and comprises a front side, a rear side, a top side, a bottom side, a length, a width, and a height, and wherein the reference edge is at least a part of the length of the main body.
Another aspect is the tile leveling tool, wherein the at least one adjustable spacer of the tool comprises: a threaded bolt configured to be removably threaded into the main body through a threaded aperture thereof, wherein the threaded bolt comprises a front end and a rear end, wherein the rear end is configured to extend out of the rear side; and a leveling pad pivotally coupled to the rear end of the threaded bolt at a joining point proximate a center of the leveling pad; wherein the joining point is movable between the rear side of the main body and the uneven installation surface when the threaded bolt moves in the threaded aperture, and wherein the leveling pad is configured to engage with the installation surface.
A further aspect is the tile leveling tool, wherein the main body of the tool further comprises a recess configured to accommodate the leveling pad such that the leveling pad does not extend out of the rear side in a configuration.
Yet another aspect is the tile leveling tool, wherein the at least one adjustable spacer of the tool comprises: a set screw configured to be removably threaded into the main body through a threaded aperture thereof from the front side, wherein the set screw comprises a front end and a rear end, wherein the rear end is configured to extend out of the rear side, an axle pin mounted on the rear side of the main body proximate the threaded aperture, wherein the axle pin is elongated along the width of the main body; a leveling pad comprising a proximal edge and a distal edge, wherein the proximal edge is connected to the axle pin, and wherein the leveling pad is pivotally connected about the axle pin; wherein, the set screw is configured to move rearwardly along the threaded aperture to cause the rear end of the set screw to contact and push the leveling pad at a point proximate the axle pin and to cause the distal edge of the leveling pad to move rearwardly.
Another aspect is the tile leveling tool, wherein the anchor of the tool is a screw adapted to be threaded into the main body through a compatible screw hole thereof from the front side, wherein the screw has a sufficient length and is configured to be threaded into the installation surface to secure the main body.
A further aspect is the tile leveling tool, wherein the interlocking element of the tool comprises a female end and a male end each placed on one of the two opposed ends of the main body, and wherein the female end is configured to mate with the corresponding male end of another tool such that the two tools are interlocked and aligned in the longitudinal axis thereof.
Yet another aspect is the tile leveling tool, wherein the male end of the interlocking element comprises at least one insert pin protruding from the end of the main body, and the female end comprises at least one insert hole corresponding to the at least insert pin, wherein the insert pin and insert hole are compatible in size, position, and orientation.
Another aspect is the tile leveling tool, wherein the tool further comprises an attracting element placed on each of the two opposed ends of the main body, wherein the attracting element is configured to attract a corresponding attracting element placed on another tool. The attracting element can be a pair of magnets or a magnet and a steel washer.
A further aspect of the tile leveling tool, wherein the tool comprises at least one visual leveling indicator placed on the main body.
In another possible configuration and by non-limiting example, a system for leveling and aligning tiles is disclosed. Various aspects are described in this disclosure, which include, but are not limited to, the following aspects.
One aspect is a system for leveling and aligning tiles, wherein the system comprises at least two tile leveling tools described herein.
Another aspect is the system, wherein the system comprises a sliding tool configured to be slid over the reference side of the tool secured on the installation surface and the tiles installed on the installation surface to cause the tiles be to leveled co-planar with the reference side.
A further aspect is the system, wherein at least 2 tile leveling tools are interlocked along the longitudinal axis to form a track, wherein the track comprises an extended reference side that is co-planar and an extended reference edge that is straight.
In further possible configuration and by non-limiting example, a method for arranging tiles on an uneven installation surface is disclosed. Various aspects are described in this disclosure, which include, but are not limited to, the following aspects.
One aspect is a method for arranging tiles on an uneven installation surface, wherein the method comprises: placing the tile leveling tool described herein on or near an uneven installation surface, with a rear side of the tile leveling tool facing the installation surface; adjusting a space between the rear side of the main body of the tile leveling tool and the installation surface by the at least one adjustable spacer of the tile leveling tool to arrange the reference edge straight across the uneven installation surface and to guide the installation of the tiles evenly; anchoring the tile leveling tool to the installation surface; and arranging tiles on the installation surface such that at least some of the tiles are aligned along the reference edge and are positioned co-planar with the reference side.
Another aspect is the method, wherein the method further comprises: connecting a plurality of the tile leveling tool using the interlocking element each thereof to form a track along the longitudinal axis, wherein the track comprises an extended reference side that is co-planar and an extend reference edge that is straight; anchoring the track on the installation surface; and arranging tiles on the installation surface such that at least some of the tiles are aligned along the extended reference edge and are positioned co-planar with the extended reference side.
A further aspect is the method, wherein the method further comprises: forming a plurality of the track, each track comprising an extended reference side and an extended reference edge; orienting the track on the installation surface to define an installation area, wherein the extended reference side of each track are co-planar; anchoring the tracks on the installation surface; and arranging tiles in the installation area such that at least some of the tiles are aligned along the extended reference edges and are positioned co-planar with the extended reference sides.
Yet another aspect is the method, wherein the method further comprises: using a sliding tool to slide over the reference side of the tile leveling tool secured on the installation surface and the tiles installed on the installation surface to cause the tiles leveled co-planar with the reference sides of the tracks.
Another aspect is the method, wherein the method further comprises: applying cement onto the installation surface; and installing the arranged tiles permanently on the installation surface.
The features, functions, and advantages described herein may be achieved independently in various implementations described in the present disclosure or may be combined in yet other implementations, further details of which may be seen with reference to the following description and drawings.
Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing. Corresponding reference characters indicate corresponding parts throughout the drawings.
Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.
The present disclosure relates to tools, systems, and methods that can be used to arrange tiles to be installed on an installation surface, guide installation of tiles, level and align tiles, such that the tiles can be installed on the installation surface properly to provide a finished tile surface that is flat, even, smooth, in-plane, durable, safe, and long-lasting.
In the example shown in
In some embodiments, the installation surface 30 is an uneven installation surface and includes at least one defect or imperfection. Non-limiting examples of the defect or imperfect include a dip, a ridge, a curved region, a concave or convex region, an out-of-plane region, an uneven area, a textured or rough area. As illustrated in
Now referring to
As illustrated in the example, the tool 200A comprises a main body 202 and at least one adjustable spacer 204. As a note, the tool 200A may be composed of various individual components that can be separated apart (
As illustrated in the example, the main body 202 has a substantially rectangular cuboid configuration and includes a first end 212, a second end 214, at least one reference side 222, at least one reference edge 224, a front side 232, a rear side 234, a top side 236, a bottom side 238, four longitudinal edges 242, a length (L), a width (W), and a height (H).
The main body 202 can be made of any material that is rigid, durable, impact-resistant, and/or chemical-resistant. Non-limiting examples of the material used for the main body 202 include wood, metal, ceramic, plastic, composite, reinforced material, or engineered material. The main body 202 may optionally have a coating layer disposed on an outer surface thereof. The coating layer may be protective, cleanable, colored, writable, or of other functions.
In the illustrated example, the main body 202 is extended from the first end 212 to the second end 214 along a longitudinal axis 216 thereof. In some embodiments, the reference side 222 is flat or substantially flat and can be a part of any of the front side 232, the rear side 234, the top side 236, and/or the bottom side 238. The reference edge 224 is straight or substantially straight and can be any of the four longitudinal edges 242. The front side 232 is configured to be exposed to an installer when in use. The rear side 234 is configured to face the installation surface when in use. In some embodiments, at least a part of the front side 232 is used as the reference side 222, which provides a reference level plane for an installer to guide tiles leveling and alignment. In some embodiments, the reference edge 224 can be any of the at least one longitudinal edge 242, which provides a guide for an installer to level and align tiles with at least a portion of the reference edge 224.
In some embodiments, the length (L) of the main body 202 is from about 3 inches to about 200 inches, or from about 6 inches to about 100 inches, or from about 9 inches to about 50 inches, or from about 10 inches to about 25 inches, or from about 12 inches to about 18 inches. In some embodiments, the width (W) of the main body 202 is from about 0.5 inch to about 10 inches, or from about 1 inch to about 6 inches, or from about 1 inch to about 4 inches, or from about 2 inches to about 3 inches. In some embodiments, the height (H) of the main body 202 is from about 0.1 inch to about 1 inch, or from about 0.2 inch to about 0.8 inch, or from about 0.3 inch to about 0.6 inch, or from about 0.3 inch to about 0.4 inch.
In some embodiments, the main body further includes a level indicator 244. The level indicator 244 can be placed on either the front side 232, or the top side 236, or both. The level indicator 244 provides a visual guide for an installer to adjust the tool 200A to a leveled position on an installation surface.
In some embodiments, the main body 202 further includes a series of measure indicia 246. Examples of the measure indicia such as marks, ruling indicators, grooves, colored lines. The measure indicia 246 allows an installer to measure size of tiles or monitor spaces between adjacent tiles.
In the illustrated example, the threaded bolt 252 is configured to be removably threaded into the main body 202 through a threaded aperture 262 thereof. The threaded aperture 262 may be pre-existing and compatible with the threaded bolt 252 in size and orientation. Alternatively, the threaded aperture 262 may be generated in situ when the threaded bolt 252 is threaded into the main body 202.
In one possible configuration as shown in
In the illustrated example, the leveling pad 254 has a relatively thin configuration and comprises a front surface 264 and a rear surface 266. The leveling pad 254 is pivotally coupled to the rear end 258 of the threaded bolt 252 at a joining point proximate a center of the front surface 264. The leveling pad 254 is pivotable relative to the rear end 258 and can form an angle (α) relative to the threaded bolt 252. As illustrated in
In some embodiments, the main body 202 further comprises a recess 270 on the rear side 234. The recess 270 is configured to accommodate the leveling pad 254 of the adjustable spacer 204. The recess 270 has a depth that is no less than the thickness of the leveling pad 254. In some embodiments, the depth of the recess 270 is in a range from about 0 to about 0.25 inch, or from about 0.05 to about 0.20 inch, or from about 0.1 to about 0.15 inch. In one possible configuration as shown in
In operation, an installer can move the threaded bolt 252 to adjust a distance between the rear side 234 of the main body and the leveling pad 254. The distance (D) is adjustable in a range from about 0 to about 1 inch, or from about 0 to about 0.8 inch, or from about 0 to about 0.6 inch, or from about 0 to about 0.5 inch.
In some embodiments, the tool 200A further includes at least one anchor 272. The anchor 272 comprises a fastening mechanism that is configured to removably secure the tool 200A on an installation surface where tiles are to be installed on. In the illustrated example, the anchor 272 is a threaded screw such as a drywall screw that can be threaded into the main body 202 through an aperture 274 from the front side 232. The aperture 274 may be pre-existing and compatible with the anchor 272 in size and orientation. Alternatively, the aperture 274 may be generated in situ when the anchor 272 is threaded into the main body 202. The anchor 272 has a length that is greater than the height (H) of the main body 202 such that the anchor can be threaded through the main body 202 and into an installation surface facing the rear side 234 of the main body 202. When secured onto an installation surface by the anchor 272, the tool 200A can be immobilized and remain a position unchanged until the anchor 272 is detached from the installation surface. In some embodiments, the tool 200A includes a plurality of anchors 272. The plurality of anchors 272 may be aligned along the longitudinal axis 216 approximate a center line of the front side 232 of the main body.
In some embodiments, the tool 200A further includes an interlocking element 278. The interlocking element 278 is configured to removably connect the tool 200A to another tool 200A along the longitudinal axis 216. In the illustrated example, the interlocking element 278 includes a female end 278A and a male end 278B. The female end 278A includes at least one insert hole located on the first end 212. The male end 278B includes at least one insert pin placed on the second end 214. In the illustrated example, the insert pins of the male end 278B protrude from the second end along the longitudinal axis 216. The insert pins of the male end 278B correlate to the insert hole of the female end 278A in size, relative position, and orientation, such that two or more tools 200A can be connected end-to-end along the longitudinal axis 216 to form the track 102.
In some embodiments, the tool 200A further includes at least one attracting element 280. In the illustrated example, the attracting element 280 includes a pair of magnets 280A, or a magnet 280A and a steel washer 280B. In some embodiments, the magnet 280A is placed on each of the first end 212 and the second end 214 of the main body 202. In other embodiments, a magnet 280A is place on the first end 212, and the steel washer 280B is placed on the second end 214. The attracting element 280 of the tool 200A is configured to attract an attracting element 280 of another tool 200A when the two tools 200A are connected and interlocked. The attraction between the attracting elements 280 may further improve the interlocking strength of the connected tools 200A.
As illustrated in the example, the tool 200B includes a main body 202 and at least one adjustable spacer 300. Similar to the tool 200A, the tool 200B may be composed of various individual components that can be separated apart (
In the illustrated example, the adjustable spacer 300 of the tool 200B includes a set screw 302, a leveling pad 304, and an axle pin 306. The set screw 302 and the leveling pad 304 can be separated apart. The set screw 302 extends from a front end 312 to a rear end 314. The set screw 302 has a length that is less than the height (H) of the main body 202. The set screw 302 is configured to be removably threaded into the main body 202 through a threaded aperture 262 thereof. The threaded aperture 262 may be pre-existing and compatible with the set screw 302 in size and orientation. Alternatively, the threaded aperture 262 may be generated in situ when the set screw 302 is threaded into the main body 202.
In one possible configuration as shown in
In the illustrated example, the leveling pad 304 has a relatively thin and substantially flat configuration. The leveling pad 304 includes a proximal edge 320, a distal edge 322, a front surface 324, a rear surface 326, and an opening 328. The opening 328 is proximate the proximal edge 320, between the front surface 324 and the rear surface 326, and through the leveling pad 304. The opening 328 substantially aligned with the proximal edge 320 and is configured to accommodate the axle pin 306.
The axle pin 306 is configured to be mounted on the rear side 234 of the main body 202 along the width (W) thereof. In one possible configuration, the axle pin 306 is inserted into the leveling pad 304 through the opening 328 and mounted on the rear side 234 proximate the rear end 314 of the set screw 302.
In some embodiments, the main body 202 includes a recess 270 as described above. The recess 270 is configured to accommodate the leveling pad 304 and the axle pin 306. In one possible configuration, the leveling pad 304 can entirely reside in the recess 270 such that the leveling pad 304 does not extend out of the rear side 234.
In the illustrated example, the leveling pad 304 is configured to move pivotally about the axle pin 306 by an angle (β). The angle (β) can be in a range from about 0 to about 90 degrees, or from about 0 to about 60 degrees, or from about 0 to about 45 degrees, or from about 0 to about 30 degrees. In operation, an installer can move the set screw 302 rearwardly to cause the rear end 314 of the set screw 302 to contact and push the leveling pad 304 at a point proximate the axle pin 306 and to simultaneously cause the distal edge 322 to move rearwardly away from the rear side 234 by a distance (D) from about 0 to about 1 inch, or from about 0 to about 0.8 inch, or from about 0 to about 0.6 inch, or from about 0 to about 0.5 inch.
In the illustrated embodiment, the main body 202 of the tile leveling tool 200B has a rectangular cuboid configuration and has a length (L) of about 24 inches, a width (W) of about 2 inches, and a height (H) of about 0.75 inch. The main body 202 comprises a plurality of threaded apertures 274 along the longitudinal axis 216 of the main body 202. The threaded apertures 274 are compatible in size with the anchor 272.
The adjustable spacer 300 includes a set screw 302, a leveling pad 304, and a axle pin 306. The leveling pad 304 has rectangular and relatively thin configuration. The leveling pad 304 has a length of about 2 inches, a width of about 0.75 inch, and a thickness of about 0.5 inch.
The main body 202 further comprises a recess 270 configured to accommodate the leveling pad 304. The recess 270 has a slightly larger dimension than that of the leveling pad 304, with a length of about 2.25 inches, a width of about 0.875 inch, and a thickness of about 0.5 inch.
The leveling pad 304 is pivotally connected to the axle pin 306. The axle 306 is mounted on the main body 202 such that the leveling pad is capable of residing in the recess 270 in one configuration and pivotal about the axle pin 306. The axle 306 further comprises a flat head 308 that can be used as a hinge.
The interlocking element 278 includes a female end 278A and a male end 278B. The female end 278A includes two insert holes located on the first end 212. The male end 278B includes two insert pins placed on the second end 214. The two insert pins 278B protrude from the second end 214 and have a distance of about 1.25 inches between each other.
The attracting element 280 includes a pair of magnets 280A that are respectively placed on the first end 212 and 214 between the two insert holes or between the two insert pins.
Now referring to
In the illustrated examples, the track 102 includes two tools 200, at least one extended reference side 108, and at least one extended reference edge 106. The two tools 200 can be either two tools 200A (
In the illustrated examples, the extended reference side 108 includes the two corresponding reference sides 222 with respect to the two connected tools 200. Similarly, the extended reference edge 106 includes the two corresponding reference edges 224 with respect to the two connected tools 200.
It is noted that the track 102 of
In some embodiments, the track 102 may include a number of tools 200, wherein the number is greater than 2. For example, the number can be at least 3, at least 4, at least 5, at least 6, at least 8, or at least 10, or at least 15, or at least 20. The track 102 advantageously allows an installer to build the length of reference sides and edges that are needed for an installation surface in any size and allows the tools to be reusable for tile installation.
Now referring to
In the illustrated example of
In the illustrated example of
In the illustrated examples of
Now referring to
In the illustrated example, the tile leveling system 100 includes two tracks 102 (102A and 102B), and a sliding tool 104. Each of the tracks 102 includes two interlocked tools 200A. The two tracks 102 are anchored on an uneven installation surface 30 and are parallel to each other. The adjustable spacers 204 of the tracks 102 are configured to adjust the space 42 between the tracks 102 and the uneven installation surface 30 and adjust the tracks 102 to the level plane 38. The two tracks 102 provide extended reference edge 106A and 106B and extended reference sides 108A and 108B. The tile leveling system 100 provides a guide for an installer to align tile edges 22 along with the extended reference edges 106A and 106B. In some embodiments, the tile edges 22 can be aligned with at least a part of the extended reference edge 106A. In some embodiments, a series of spacers can be disposed between the tile edges 22 and the extended reference edge 106A to set a desired space between the tile edges 22 and the extended reference edge 106A. The tile leveling system 100 also provides the level plane 38 that is defined by the extended reference sides 108A and 108B, which can be used as a guide for the tiles 20 to be leveled and aligned in the level plane 38.
In the illustrated example, the sliding tool 104 is configured to be slid over the extended reference sides 108A and 108B of the two tracks 102 and the tiles 20. The sliding tool 104 is further configured to tamp down on the tiles 20 when sliding over the tiles 20 to compress the mortar or cement 40 disposed in the space 42 and to cause the tiles 20 be to leveled co-planar with the extended reference sides 108A and 108B. If tiles 20 are arranged and tamped down too much by the sliding tool 104, then the tiles 20 may be removed and more mortar or cement 40 is disposed in the space 42 to allow the tiles 20 be re-arranged by the tile leveling system 100.
In the illustrated example of
Now referring to
In some embodiments, the method 400 further includes operations 410 and 412. Operation 410 includes applying mortar or cement 40 onto the installation surface 30 to fill the space 42 between the between the rear side 234 of the tool 200 and the installation surface 30. The amount of the mortar may vary depending on level of deviation across the entire installation surface 30. If the tiles 20 are not aligned with the reference side 222, the tiles 20 can be re-arranged by adjusting the amount of mortar to an appropriate level that allows the tiles 20 to be aligned with the reference side 222. Operation 412 includes installing the arranged tiles 20 permanently on the installation surface 30. At operation 412, the tiles are leveled along the reference edge 224 and aligned with the reference side 222. The leveled and aligned tiles 20 are permanently installed on the installation surface 30 once the mortar disposed between the tiles 20 and the installation surface 30 is dried. The installed tiles that are leveled and aligned by the tool 200 provide a flat, even, and flawless tile surface that is leveled and co-planar with the level plane 38.
In some embodiments, the method 600 further includes operations 410, 612, and 412. Operation 410 includes applying mortar onto the installation surface 30. The mortar can fill the space between the track 102 and the installation surface 30. Operation 612 includes sliding over the extended reference sides 108 and the tiles 20 using a sliding tool to tamp down on the tiles 20. At operation 612, the mortar disposed in the space can be compressed by the sliding tool 104 to further level the tiles across the entire installation surface 30. The leveled tiles are co-planar with the level plane 38. Operation 412 includes installing the arranged tiles permanently on the installation surface that is described above.
The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims.
This application is a continuation of U.S. application Ser. No. 17/349,691, filed Jun. 16, 2021, which claims priority to U.S. Provisional Application No. 63/039,944, filed Jun. 16, 2020, which are hereby incorporated by reference in their entireties. To the extent appropriate a claim of priority is made to each of the above-disclosed applications.
Number | Date | Country | |
---|---|---|---|
63039944 | Jun 2020 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 17349691 | Jun 2021 | US |
Child | 18437069 | US |