AU2013206234A1 - A tile levelling device and method - Google Patents

Abstract

Abstract The present invention relates to a tile levelling device and method of forming a tile levelling device. The tile levelling device is of a type that uses a wedge to achieve levelling of the tiles. The tile levelling device includes a first component 20 and a second component 200. The first and second components 20, 200 are arranged to be connected together so as to form a vertical member V and a horizontal member H. The vertical member V in use extends upwardly of the horizontal member H establishing a first tile seat on one side of the vertical member V and a second tile seat on the other side of the vertical member V. The vertical member V is arranged to be removable from the horizontal member H either in whole or in part after the tile levelling device 10 has been used to level tiles located on the first and second tile seats. The removed vertical member V can then be used as a "salvaged" second component for another tile levelling device. 2zb (0 0o goo

Description

1 Title of Invention A Tile Levelling Device and Method Technical Field [0001] The present invention relates to a device for levelling tiles, such as floor tiles, and a method of doing the same. The tile levelling device is of the type that is used in conjunction with a wedge. Background of Invention [0002] Tiles are normally laid on a floor or wall or other flat surface using an adhesive. The adhesive is typically troweled onto the flat surface and also onto the rear side of the tile. The tile is then positioned on the surface at the required position. Spacers are normally used between adjacent tiles to ensure that the width of the gaps between adjacent tiles is even. [0003] In addition to ensuring that the width of the gaps between the tiles is even across an entire floor, the installer also needs to ensure that the tiles are laid flat. The upper surfaces of all the tiles of a floor need to be located in the same plane across the floor. When large tiles are being installed it is more difficult to ensure that the tiles are laid correctly. Accordingly, devices for levelling adjacent tiles have been developed. [0004] Australian patent 2008231348 describes different tile levelling devices. For example, as shown in Figure 1 of Australian patent 2008231348, a tile levelling device includes a levelling member 10 and a wedge 12. The levelling member 10 has a vertically aligned member 14 and a generally horizontally curving member 16. The vertical member 14 extends from the horizontally curving member 16. A breakaway line 22 is defined on the vertical member 14 on either surface proximate the horizontal member 16. The breakaway line 22 is defined by removing material from either surface of the vertical member 14 such that the thickness of the vertical member 14 along the line 22 is reduced and the vertical member 14 is weaker along the line 22. [0005] The levelling member 10 is placed in use such that the end of a tile sits on one end of the horizontal member 16 and abuts one surface of the vertical member 2 14 and an adjacent tile sits on the other end of the horizontal member 16 and abuts an opposite surface of the vertical member 14. The wedge 12 is then pushed through an opening 20 in the vertical member 14. Due to its increasing thickness, the wedge 12 causes the edge of each tile to be compressed downward pressing the horizontal member 16 beneath it towards the subsurface. As a result the adjacent tiles are aligned and levelled. The spacing between the tiles is controlled by the thickness of the vertical member 14. [0006] Once the tiles are set, the vertical member 14 along with the wedge 12 is broken off by kicking or applying a sideways type force to the vertical member 14. This causes the vertical member 14 to break along the breakaway line 22. [0007] The portion of the vertical member 14 which is broken away must be collected by the installer and later discarded. This results in considerable wastage. [0008] Australian Innovation Patent 2012101175 shows another form of tile levelling device. The tile levelling device includes an upper portion that is broken from and discarded after use of the levelling device. The levelling device uses a wedge to level the adjacent tiles. [0009] The present invention seeks to provide a tile levelling device and method of forming a tile levelling device that eliminates the wastage of prior art arrangements such as those described previously. [0010] The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of this application. Summary of Invention [0011] According to one aspect of the present invention there is provided a tile levelling device including a first component and a second component, the first and second components arranged to be connected together so as to form a vertical member and a horizontal member, the vertical member extending from the horizontal member, the vertical member and horizontal member establishing a first tile seat on one side of the vertical member and a second tile seat on the other side of the vertical 3 member, and wherein the vertical member is arranged to be removed from the horizontal member either in whole or in part after the tile levelling device has been used with a wedge or other like device to level tiles located on the first and second tile seats. [0012] Each of the first and second components preferably has a generally planar configuration. The first component includes a tab, a tab aperture and a wedge aperture. The second component includes a tab aperture. The tab of the first component and the tab aperture of the second component are shaped and positioned so that the tab of the first component can be received in the tab aperture of the second component and engaged therein so that the first and second components when connected together form the vertical member and the horizontal member. [0013] The tab and the tab aperture may adopt varying different configurations. However, in accordance with an embodiment of the invention, the tab is located on a first edge of the first component and is generally T-shaped. The tab includes a depending part and first and second fingers. The tab aperture of the second component is also generally T-shaped and is configured so that the tab of the first component can be positioned in the tab aperture of the second component by moving the first component in a first direction. The first component is then moved in a second direction until the first and second fingers of the tab on the first component locate under the second component and the first and second components engage together. The first and second directions are preferably substantially perpendicular to one another. [0014] The wedge aperture is arranged to receive a wedge or other like device and is preferably square or rectangular in shape. [0015] Each of the first and second components preferably includes a first and a second face. At least one raised portion is located on each of the first and second faces. The raised portion preferably is formed as a raised strip extending from the first edge to an opposed second edge. Preferably two raised portions are located on each of the first and second faces and the tab aperture is located between the raised portions.

4 [0016] The first and second components are preferably made from a plastics material. [0017] The invention further provides a first component for a tile levelling device, said first component including a body with a tab, a tab aperture and a wedge aperture, the tab arranged to be received in the tab aperture of a second component and engaged therein so that the first and second components when connected together form a vertical member and a horizontal member. [0018] The tab aperture of the first component is preferably identical in configuration to the tab aperture of the second component. [0019] According to a second aspect of the present invention there is provided a method of forming a tile levelling device, said method including the steps of: obtaining a first component and a second component, the first component including a body with a tab, a tab aperture and a wedge aperture, the second component including a body with a tab aperture, and locating the tab of the first component with the tab aperture of the second component so that the first and second components form a vertical member and a horizontal member, the vertical member extending upwardly of the horizontal member establishing a first tile seat on one side of the vertical member and a second tile seat on an other side of the vertical member. [0020] The first tile seat is preferably arranged so that in use an end of a first tile sits on a part of the horizontal member located on the one side of the vertical member. The second tile seat is arranged so that in use an end of a second tile sits on a part of the horizontal member located on the other side of the vertical member. The vertical member extends upwardly between adjacent end faces of the first and second tiles. [0021] In accordance with an embodiment of the invention, the tab of the first component and the tab aperture of the second component are shaped and positioned so that the tab of the first component can be received in the tab aperture of the second component and engaged therein so that the first and second components when connected together form the vertical member and the horizontal member of the levelling device.

5 [0022] The vertical member is preferably arranged to be removable from the horizontal member either in whole or part after the levelling device has been used to level tiles located on the first and second tile seats. The vertical member will not normally be removed until an adhesive used to secure the tiles in position has gone off or set. [0023] The removed vertical member is preferably collected by the installer and saved for use at a later date. At the later date, when forming a second tile levelling device, the removed vertical member from the used first tile levelling device is obtained and becomes a second component for connection to a first component of the second tile levelling device. When the second tile levelling device has been used to level tiles located on the first and second tile seats, the vertical member of the second tile levelling device is removed and is collected by the installer for use at a later date. At the later date, when forming a further tile levelling device, the removed vertical member from the used second tile levelling device is obtained and becomes a second component for connection to a first component of a further tile levelling device. It will thus be appreciated that the vertical member of an earlier tile levelling device is retained for use as the second component of a later formed tile levelling device and in this way the vertical member can be reused rather than being discarded. [0024] It will be appreciated that when the vertical member is removed from the horizontal member after the levelling device has been used to level tiles located on the first and second tile seats, some damage to the vertical member may occur. Indeed removal of the vertical member from the horizontal member of a levelling device will typically result in some part of the vertical member being damaged or even perhaps broken away. For example, the tab of the first component that forms the vertical member may be damaged. However, the removed vertical member is not so damaged that it cannot be later used to form a second component of a subsequent tile levelling device. Brief Description of Drawings [0025] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: 6 [0026] Figure 1 is an isometric view of first and second components of a tile levelling device in accordance with an embodiment of the invention. [0027] Figure 2 shows the first and second components of Figure 1 arranged with the tab of the first component in the tab aperture of the second component. [0028] Figure 3 shows the first and second components of Figure 1 connected together to form the levelling device. [0029] Figure 4 is a cross-sectional view along a line through the raised strips of the first and second components and showing the tile levelling device with tiles located on the first and second tile seats. [0030] Figure 5 shows the vertical member of the tile levelling device once removed from the horizontal member following use of the tile levelling device. Figure 5 depicts a device formed from two "new" components. [0031] Figure 6 is an underneath view of a tile levelling device formed from a first component as shown in Figure 1 and a second component that is the removed vertical member shown in Figure 5. [0032] Figure 7 is an isometric view of a tile levelling device according to a second embodiment of the invention. Detailed Description [0033] Tile levelling devices of embodiments of the present invention are constructed by assembling together two components. When an installer uses such tile levelling devices for the first time, the first and second components will both be "new" components. The term "new" is used in this instance to indicate that the components have not previously been used to form a tile levelling device in accordance with an embodiment of the invention. However, after the first tile laying job is completed, the installer will have obtained a supply of "salvaged" parts. The term "salvaged" is used in this instance to indicate a vertical member that has been removed from an earlier used tile levelling device. The removed vertical member previously formed at least a part of the first component of the earlier used tile levelling device. The "salvaged" vertical member can then be used by the installer as a 7 second component of another tile levelling device. The "salvaged" second component when joined to a "new" first component forms the horizontal member of a subsequently assembled tile levelling device. As will be explained in detail below, that horizontal member is left under the tiles once they have been secured to the floor or flat surface and is thus not available for re-use. [0034] Figures 1 to 5 illustrates a tile levelling device 10 made from "new" first and second components 20, 200. The first and second components 20, 200 are identical. In contrast, Figure 6 illustrates a tile levelling device 10' assembled from a "new" first component 20 and a "salvaged" second component 200'. [0035] As shown most clearly in Figures 1 to 3, the tile levelling device 10 is assembled from first and second components 20, 200 that are identical. Accordingly, only the configuration of the first component 20 will be hereafter detailed. [0036] The first component 20 has a generally planar rectangular shaped body 22 with opposed first and second faces 22a, 22b. The first component 20 further includes a tab 24, a tab aperture 26 and a wedge aperture 28. As illustrated, the tab 24 is generally T-shaped and is located on a first edge 30a of body 22. The tab 24 includes a depending part 24a and first and second generally outwardly extending fingers 24b, 24c. [0037] The tab aperture 26 is also generally T-shaped and includes a tab entry part 26a and a tab engaging part 26b. The functions of parts 26a, 26b will become apparent form subsequent description. [0038] The wedge aperture 28 adopts a shape suitable to enable a wedge, wedge member or other like device (not shown) to be wedged in the wedge aperture 28 during a tile levelling step. The wedge aperture 28 and wedge (not shown) are configured to operate in a manner similar to the wedge and opening of the tile levelling device shown in Australian patent 2008231348 and described herein previously. [0039] A pair of raised portions in the form of raised strips 32 is formed on each of the first and second faces 22a, 22b of the body 22 of the first component 20. Each strip 32 extends from the first edge 30a of the body 22 to a second opposed edge 8 30b. As shown, the tab aperture 26 and wedge aperture 28 are located between the two raised strips 32. [0040] The tab 24 of the first component 20 is arranged so that it can be positioned in the tab aperture 26 of the second component 200. As understood by a comparison of Figures 1 and 2, the tab 24 of the first component 20 is moved into the tab entry part 26a of the tab aperture 26 of the second component 200 by moving it downwardly in a first direction A. The tab 24 of the first component 20 is moved into the tab entry part 26a of the tab aperture 26 of the second component 200 until the first edge 30a contacts the first face 22a of the second component 200. In this position, the first and second fingers 24b, 24c of the tab 24 of the first component 20 are located generally below the plane of the second face 22b (see Figure 4) of the second component 200. [0041] The first component 20 is then moved in a second direction (indicated by arrow B) so that the depending part 24a of the tab 24 of the first component 20 travels along the tab engaging part 26b of the tab aperture 26 of the second component 200 until it strikes opposed protrusions 26c. Pressure is then applied to the first component 20 in the first direction A to push the first component 20 past the protrusions 26c so that the first component 20 is located in the position shown in Figure 2. The fit between the engaging parts of the first and second components 20, 200 is such that the first and second components 20, 200 connect together so as to establish a tile levelling device 10 including a vertical member V and a horizontal member H. The first components 20 must be deliberately moved back past the protrusions 26c on the second component 200 in order to disconnect the components 20, 200. [0042] Once the installer has assembled the tile levelling device 10 using the first and second components 20, 200 it is ready for use. The tile levelling device 10 is used in a manner similar to that of the device described previously in Australian patent 2008231348. More particularly, and as shown in Figure 4, the tile levelling device 10 is positioned on the surface being tiled so that it is at least in part embedded in tile adhesive 300. A first tile 400 is then laid so that the underside of the end of the tile 400 locates on a first part of the horizontal member H and the end face of the tile 400 is located adjacent to the vertical member V. It will thus be appreciated 9 that in this manner the vertical member V and horizontal member H form a first tile seat. [0043] A second tile 500 is then laid so that the underside of the end of the tile 500 locates on a second part of the horizontal member H and the end face of the tile 500 is located adjacent to the vertical member V. It will thus be appreciated that in this manner the vertical member V and horizontal member H form a second tile seat. [0044] The vertical member V also thereby establishes a minimum space between the first and second tiles 400, 500. The minimum space between the first and second tiles 400, 500 will be determined by the widest dimension of the vertical member V which is the width of the vertical member V including the width of the raised strips 32 formed on both faces 22a, 22b of the body 22 of the first component 20. [0045] Although not apparent from Figure 4, it will be appreciated that adhesive 300 may be located above the horizontal member H and below that part of the tile 400, 500 located on the first and second seats. Similarly, adhesive 300 may be located between the end face of each tile 400, 500 and the vertical member V. [0046] Once the tiles 400, 500 are in position on the tile levelling device 10, a wedge (not shown) is located in the wedge aperture 28 and is driven into the aperture 28 until the tiles 400, 500 are levelled by contact with the underside of the wedge. The installer then continues to lay further tiles over the surface in a similar manner until all of the required tiles are laid. [0047] Once the adhesive has gone off, the wedges and levelling device are removed together by the installer kicking or hitting them with a rubber mallet to lift the vertical member V and wedge upwardly away from the tiles 400, 500. The vertical member V and wedge can then be separated and sorted for re-use later. [0048] The upward force applied to the vertical member V causes some deflection of the fingers 24b, 24c of the tab 24 of the first component 20 which are located underneath the horizontal member H (Figure 4). This deflection enables the fingers 24b, 24c to be pulled out of the tab aperture 26 in the second component 200 and thus release them from below the horizontal member H. In some instances, the fingers 24b, 24c may be caused to be snapped off and left under the horizontal 10 member H. In other instances, the fingers 24b, 24c may just be deformed and may not actually separate from the vertical member V. [0049] Removal of the vertical member V is made easier because of the inclusion of the raised strips 32 formed on both faces 22a, 22b. These strips 32 have of the effect of limiting the contact area between the vertical member V of the levelling device 10 and the end face of each tile 400, 500, whilst still effectively spacing the tiles 400, 500. [0050] The removed vertical member V is collected by the installer and is saved or "salvaged" for use at a later date. At the later date, when forming a second tile levelling device 10' as shown in Figure 5, the removed vertical member V from the first tile levelling device 10 is obtained and becomes a second component 200' for connection to a first component 20 of the second tile levelling device 10'. [0051] Assembly of the second tile levelling device 10' is similar to that of the first tile levelling device 10. The only difference is that the second component 200' is a "salvaged" component. This is clearly shown in Figure 5, where the "salvaged" component 200' is shown with the fingers 24b, 24c of the tab 24 totally removed. There is however still enough of the depending part 24a of the tab 24 of the second component to locate within the tab aperture 26 of the first component 20 and to firmly connect the "salvaged" second component 200' to the first component 20. The shape and size of the depending part 24a relative to the tab aperture 26 and the protrusions 26c of the first component 20 enable this connection. [0052] When the second tile levelling device 10' is used, the "salvaged" second component 200' forms the horizontal member H whilst the "new" first component 20 forms the vertical member V. [0053] Once the installer has laid the required tiles and the adhesive has gone off, the vertical member V is removed from the second levelling device 10' in the manner described in relation to the first levelling device 10. The vertical member V of the second tile levelling device 10' is removed and is collected by the installer for use at a later date. At the later date, when forming a further tile levelling device, the removed vertical member V from the used second tile levelling device 10' is obtained and becomes a second component for connection to a first component of a further tile 11 levelling device. It will thus be appreciated that the vertical member V of an earlier tile levelling device establishes the second horizontal component of a later formed tile levelling device and in this way the vertical member V can be reused rather than just being discarded. [0054] It will be appreciated that when the vertical member V is removed from the horizontal member H after the tile levelling device of an embodiment of the invention has been used, some damage to the vertical member V may occur. Indeed removal of the vertical member V from the horizontal member H of a levelling device will typically result in some part of the vertical member V being damaged or even perhaps broken away. For example, the tab 24 of the first component 20 that forms the vertical member V may be damaged. However, the removed vertical member V is not so damaged that it cannot be later used to form a second component 200' of a subsequent tile levelling device 10. It will be understood, that in use the second component 200' is located generally horizontally under the tiles 400, 500 and that the second component 200' does not need a tab 24 to perform its operational function. [0055] Figure 7 illustrates a tile levelling device 1000 according to an alternative embodiment of the invention. The tile levelling device 1000 is similar to the device 10 shown in the earlier Figures. However it will be noted that the tile levelling device 1000 includes a raised or thickened portion or strip 1050 located preferably on either side of the tile levelling device 1000. Each raised or thickened strip 1050 runs generally horizontally between the strips 32 and is positioned below the tab aperture 26a and above the first edge 30a of the body 22. The raised or thickened strip 1050 may adopt different configurations and provides additional strength to the device 1000 in the area generally above the tab 24. It is envisaged that the additional strength in this area will facilitate the fingers 24b, 24c of the tab 24 deforming or breaking away more easily and in the required manner. [0056] Embodiments of the invention are advantageous because the first and second components can be easily and quickly connected together to form a tile levelling device. The "new" first and second components are identical so that only one shape of component must be manufactured reducing production costs. The components are essentially planar making them easy to package, ship and less prone to breakage. Assembly is completed by the installer rather than the manufacturer 12 which again results in reduced production costs. Furthermore, the "salvaged" vertical member can later be used as a second component of another levelling device and thus the wastage of prior art devices is eliminated. [0057] The embodiments have been described by way of example only and modifications within the spirit and scope of the invention are envisaged.

Claims (26)

1. A tile levelling device including a first component and a second component, the first and second components arranged to be connected together so as to form a vertical member and a horizontal member, the vertical member extending from the horizontal member, the vertical member and horizontal member establishing a first tile seat on one side of the vertical member and a second tile seat on the other side of the vertical member, and wherein the vertical member is arranged to be removed from the horizontal member either in whole or in part after the tile levelling device has been used with a wedge or other like device to level tiles located on the first and second tile seats.

2. A tile levelling device according to claim 1 wherein each of the first and second components has a generally planar configuration.

3. A tile levelling device according to claim 1 or claim 2 wherein the first component includes a body with a tab, a tab aperture and a wedge aperture.

4. A tile levelling device according to claim 3 wherein the second component includes a tab aperture.

5. A tile levelling device of claim 4 wherein the tab of the first component and the tab aperture of the second component are shaped and positioned so that the tab of the first component can be received in the tab aperture of the second component and engaged therein so that the first and second components when connected together form the vertical member and the horizontal member.

6. A tile levelling device according to claim 5 wherein the tab of the first component is located on a first edge of the first component and is generally T shaped.

7. A tile levelling device according to claim 6 wherein the tab of the first component includes a depending part and first and second fingers.

8. A tile levelling device according to claim 7 wherein the tab aperture of the second component is configured so that the tab of the first component can be 14 positioned in the tab aperture of the second component by moving the first component in a first direction.

9. A tile levelling device according to claim 8 arranged so that the first component can be moved in a second direction until the first and second fingers of the tab on the first component locate under the second component and the first and second components engage together.

10. A tile levelling device according to any one of the preceding claims wherein the wedge aperture of the first component is arranged to receive a wedge member.

11. A tile levelling device according to any one of the preceding claims wherein each of the first and second components includes a first and a second face and at least one raised portion is located on each of the first and second faces.

12. A tile levelling device according to claim 11 wherein the raised portion is formed as a raised strip extending from the first edge to an opposed second edge.

13. A tile levelling device according to claim 11 including two raised portions located on each of the first and second faces and the tab aperture is located between the raised portions.

14. A tile levelling device according to any one of the preceding claims wherein the first and second components are made from a plastics material.

15. A first component for a tile levelling device, said first component including a body with a tab, a tab aperture and a wedge aperture, the tab arranged to be received in the tab aperture of a second component and engaged therein so that the first and second components when connected together form a vertical member and a horizontal member.

16. A first component according to claim 15 wherein the tab aperture of the first component is identical in configuration to the tab aperture of the second component.

17. A first component according to claim 15 or claim 16 wherein the body is planar. 15

18. A first component according to any one of claims 15 to 17 wherein the body includes a first face and a second face and at least one raised portion is located on each of the first and second faces.

19. A tile levelling device according to claim 18 wherein the raised portion is formed as a raised strip extending from the first edge to an opposed second edge.

20. A tile levelling device according to claim 18 including two raised portions located on each of the first and second faces and the tab aperture is located between the raised portions.

21. A tile levelling device according to claim 19 or claim 20 further including at least one generally horizontal raised portion located between the two raised portions and generally below the tab aperture.

22. A method of forming a tile levelling device, said method including the steps of: obtaining a first component and a second component, the first component including a body with a tab, a tab aperture and a wedge aperture, the second component including a body with a tab aperture, and locating the tab of the first component within the tab aperture of the second component so that the first and second components form a vertical member and a horizontal member, the vertical member extending upwardly of the horizontal member establishing a first tile seat on one side of the vertical member and a second tile seat on an other side of the vertical member.

23. A method according to claim 22 further including: positioning a first tile on the first tile seat, positioning a second tile on the second tile seat, locating a wedge in the wedge aperture of the first component, and wedging the wedge into the wedge aperture to level the first and second tiles. 16

24. A method according to claim 23 further including the step of: removing the wedge from the wedge aperture, and removing the vertical member from the horizontal member either in whole or part.

25. A method according to claim 24 further including the step of collecting the removed vertical member.

26. A method according to claim 24 or claim 25 further including the step of: forming a second tile levelling device by obtaining the removed vertical member, connecting the removed vertical member to a new first component to form the second tile levelling device.