WO2019071183A1

WO2019071183A1 - Integrally fabricated tile-leveling base and wedge

Info

Publication number: WO2019071183A1
Application number: PCT/US2018/054692
Authority: WO
Inventors: Giancario GIANNUNZIO
Original assignee: Giannunzio Giancario
Priority date: 2017-10-05
Filing date: 2018-10-05
Publication date: 2019-04-11
Also published as: US20200318364A1; WO2019071183A8

Abstract

A tile-leveling base and wedge are integrally fabricated. The base includes a tile-supporting platform. A base post including post proximal and distal ends has its proximal end attached to the tile-supporting platform at a first breakaway joint. A cross member perpendicularly depends from the post distal end and includes a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform and (ii) pivotable at the first breakaway joint into a position in which it is spaced apart from, and facing, the platform. The wedge includes a wedge tip, which tip, at the time of contemporaneous fabrication with the base, is attached to the base at a second breakaway joint so that the wedge can be separated from the base for use in combination with the base.

Description

INTEGRALLY FABRICATED TILE-LEVELING BASE AND WEDGE

BACKGROUND

A key objective of a quality floor or wall tile installation is ensuring that at every joint at which adjacent tiles meet, the tiles are evenly spaced and mutually level (i.e., coplanar). Depending on the layout and location of tiles within a titled space, two or four tiles may meet at a common joint, for example. Ideally, all tiles over a particular tiled area should extend along a common tile plane with no discernable deviation in heights of the tiles' upper surfaces (i.e., the surfaces visible to observers after installation).

Various apparatus and devices have been devised to aid in the leveling of tiles during installation. One common system includes a cooperating combination of tile-leveling bases and wedges. One example of such a base and wedge leveling system is produced by QEP, and sold under the tradename "LASH," which is an acronym for "level, align, space, and hold." Several manufacturers, including QEP, refer to as "clips" the structures introduced above as "bases." Throughout the remainder of the present specification, as well as the claims, the term "base" or "tile-leveling base" is employed, as well as their plural forms, "bases" and "tile-leveling bases." Although the specific configurations of the tile-leveling bases and wedges may vary among types and manufactures, the various tile-leveling bases and wedges have in common certain general elements.

A tile-leveling base includes a tile-supporting platform configured to extend, when deployed, along the tile plane and below the lower surfaces of two or more adjacent tiles. Extending perpendicularly to the tile-supporting platform is a base post. The base post extends for a predetermined distance away from the tile-supporting platform toward a post distal end. Extending perpendicularly from the base post is at least one cross member, each of which cross members includes at least one wedge-engaging surface spaced apart by a predetermined distance from, and facing, the base platform. The predetermined distance by which the base platform and the wedge- engaging surface are spaced apart is preconfigured to be larger than the thickness of the tiles with which that particular tile-leveling base is to be used. In this way, in the case of floor tile, for example, when the tile lower surfaces of adjacent tiles are resting on the base platform, there is defined a wedge gap between each tile upper surface and the wedge-engaging surface.

A wedge for use in combination with the tile-leveling base includes wedge bottom and top surfaces. The wedge bottom surface extends longitudinally between a wedge heel and wedge tip, and is configured for contactably engaging and sliding across tiles' upper surfaces. The wedge top surface also extends longitudinally between the wedge heel and tip, and along a plane nonparallel to the wedge bottom surface such that the wedge bottom and top surfaces mutually converge to define the wedge tip.

For purposes of understanding, use of a tile-leveling base and wedge is briefly described in the context of tiling a floor, as opposed to a wall, and even then only by way of non-limiting example. With a first of two tiles situated on top of still-wet setting material (e.g., mortar), a portion of the tile-supporting platform of a tile-leveling base is inserted under the tile lower surface of that first tile with the base post protruding upwardly above the tile upper surface. Next, with enough still-wet setting material spread adjacent the first tile to accommodate a second tile, the second tile is situated adjacent the first tile, with the tile lower surface of that second tile resting over a portion of the tile-supporting platform on the opposite side of the base post from the portion of the tile-supporting platform supporting the first tile. Moreover, the first and second tiles are adjacently situated such that there is defined between them a tile gap, which is later filled with grout.

With the base post extending upwardly through the tile gap between the first and second tiles, a wedge is aligned with and slidably inserted into the wedge gap defined between each tile upper surface and the wedge-engaging surface of the cross member. As the wedge is urged into the wedge gap in a direction perpendicular to the tile gap, and along the tile upper surfaces of the first and second tiles, the wedge top surface eventually engages the wedge-engaging surface of the cross member extending perpendicularly from the base post. When the wedge is thusly urged from the wedge heel with sufficient force, the cross member "rides" up the wedge top surface, thereby applying an upwardly directed tensile force to the base post and urging the base platform toward and against the tile lower surfaces. At the same time, the wedge bottom surface is being urging downwardly with equal and opposite force against the tile upper surfaces. Because the wedge bottom surface defines a single plane, the tile upper surfaces of the first and second tiles are brought into planar alignment along the tile gap defined between the first and second tiles.

Presently, tile-leveling bases are manufactured, packaged and sold separately from the wedges suitable for use with those wedges. On the manufacturing and distribution side, this fact requires separate fabrication, packaging, and display at retail of the bases and wedges. On the consumer side, care must be taken to match tile-leveling bases with properly sized wedges.

Accordingly, a need exists for a tile-leveling base and wedge that are integrally formed at the time of fabrication, but configured for ready on-site separation by a tile installer. SUMMARY

In each of various embodiments, a tile-leveling base and wedge for use with the base are contemporaneously and integrally fabricated. The manner in which the wedge and base are integrally formed may vary, as the particular method of manufacture is not central to various aspects of the invention. Although injection molding is regarded as a particularly advantageous option, alternative molding techniques, or even 3D printing, are possibilities within the scope and contemplation of the invention.

The tile-leveling base includes a tile-supporting platform with opposed platform top and bottom sides bounded by a platform periphery. A base post includes post proximal and distal ends. The tile- supporting platform and base post are formed at manufacture such that the post proximal end is attached to the tile-supporting platform by and at a first breakaway joint with a predetermined tensile strength and a predetermined shear strength.

At least one cross member depends from, and extends perpendicularly to, the post distal end. Most commonly, the cross member will simply be integrally formed as a portion of the base post itself, while also having certain discernable elements including a cross-member distal edge facing away from the tile-supporting platform. Additionally, the cross member includes at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform top side and (ii) movable into a position in which it is spaced apart by a predetermined distance from, and facing, the platform top side.

The wedge extends longitudinally along a wedge axis between a wedge heel and a wedge tip. A wedge bottom surface and an opposed wedge top surface coextend longitudinally along the wedge axis. The wedge bottom and top surfaces generally extend along respective non-parallel planes such that they mutually converge to define the wedge tip. In some embodiments, the wedge top surface is undulated in a manner defining, for example, a saw tooth or stepped profile. The reason for this will be readily appreciated by practitioners of the tile-installation profession, and even "do-it-yourself homeowners: such a surface allows the wedge, when in use with the tile-leveling base, to engage the wedge-engaging surface in increments and "click" as it is advanced between the wedge-engaging surface and tile upper surfaces.

As fabricated, various embodiments are configured such that the wedge tip is attached to the cross-member distal edge at a second breakaway joint. The second breakaway joint facilitates selective separation for use of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base. In alternative versions, the wedge tip may instead be attached by a second breakaway joint to the platform periphery.

In accordance with at least one variation, the first breakaway joint by which the base post proximal end is attached to the tile-supporting platform is a living hinge. The living hinge is configured such that the base post is pivotable relative to the tile-supporting platform between post first and second attitudes. In the post first attitude, the base post is substantially coplanar with the tile- supporting platform, while, in the post second attitude, the base post extends perpendicularly to the tile- supporting platform in a direction upwardly of the platform top side. It is to be understood that "upwardly" as used in the preceding sentence is a relative term; while the tile-leveling base may be oriented in any number of orientations in space, a "common-vernacular definition" of "upwardly" in this case indicates that, in the post second attitude, the base post protrudes away from the tile-supporting platform in the same direction that the platform top side faces.

At the time that each of various embodiments is fabricated, the base post and tile-supporting platform are formed with the base post in the post first attitude. In such instances, the post first attitude may be alternatively referred to as the "fabrication attitude." In contrast, in order to deploy the pivotable base post for use, the base post must be pivoted into or toward the post second attitude. For this reason, the post second attitude may be alternatively referred to as the "deployed attitude."

Once the tile-leveling base and wedge are separated from one another, and the base post is in the deployed attitude, the tile-leveling base and wedge are used in a manner consistent with the manner in which extant tile-leveling bases and wedges are used. Accordingly, the explanation of the use of bases and wedges provided in the background is relied upon to provide the explanation and disclosure as to how the tile-leveling based and wedges of the present invention are employed on a tiling job.

Representative embodiments are more completely described and depicted in the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tile-leveling base and wedge integrally formed; FIG. 2 is a side view of the tile-leveling base and wedge of FIG. 1 showing the base post in a post first attitude relative to the tile-supporting platform of the tile-leveling base;

FIG. 3 is a second perspective view of the tile-leveling base and wedge of FIGS. 1 and 2 in which - with the wedge and tile-leveling base still joined - the base post has been pivoted relative to the tile-supporting platform from the post first attitude to a second post attitude in which the base post extends perpendicularly to the tile-supporting platform;

FIG. 4 presents a side view of the still-joined tile-leveling base and wedge of FIGS. 1 -3 and the base post in the second post attitude;

FIG. 5 is a perspective view of the tile-leveling base and wedge of FIGS. 1 -4 after they have been separated from one another and positioned for use;

FIG. 6 is a side view showing of the same relative arrangement of the now-separated tile- leveling base and wedge in the same relative arrangement in which they are depicted in FIG. 5; and

FIG. 7 shows a plurality of tile-leveling base and wedge sets stacked for packaging.

DETAILED DESCRIPTION

The following description of variously embodied tile-leveling bases and wedges is demonstrative in nature and is not intended to limit the invention or its application of uses. Accordingly, the various implementations, aspects, versions and embodiments described in the summary and detailed description are in the nature of non-limiting examples falling within the scope of the appended claims and do not serve to restrict the maximum scope of the claims.

With conjunctive reference to FIGS. 1 -6, components of an illustrative tile-leveling base and wedge set 10 are shown and described. As depicted throughout the drawings, the tile-leveling base and wedge system 10 includes two main elements: (i) a tile-leveling base 100 and (ii) wedge 200 configured to cooperate with that tile-leveling base 100. As an initial observation, FIGS. 1-4 show the title-leveling base 100 and wedge 200 as joined (integrally formed) in their manufactured state, while FIGS. 5 and 6 show the tile-leveling base 100 and wedge 200 separated from one another, but generally positioned relative to one another in a cooperative state for leveling tiles (not shown). Each of the two main elements is the subject of detailed discussion below in conjunction with referenced drawings.

Throughout the drawings, like reference characters are used to denote like elements, regardless of whether a particular reference character is called out with reference to a particular figure in the present description. Although the major sub-elements of the tile-leveling base 100 and wedge 200 are visible in all of the drawings, they are introduced with initial reference to FIGS. 1 and 2.

The tile-leveling base 100 includes a tile-supporting platform 115 with opposed platform top and bottom sides 120 and 130 bounded by a platform periphery 135. A base post 150 includes post proximal and distal ends 152 and 154. The post proximal end 152 is attached to the tile-supporting platform 115 by a first breakaway joint JBL

The first breakaway joint JBI is configured with a predetermined tensile strength and a predetermined shear strength. More specifically, as will be appreciated by practitioners of the tile installation profession familiar with the tile-leveling bases of existing base and wedge systems, the first breakaway joint JBI should have a sufficiently high tensile strength to withstand a force sufficient to draw adjacent tiles into a coplanar alignment as the wedge 200 is used to exert an upwardly directed tensile force on the base post 150. On the other hand, the shear strength of the first breakaway joint JBI must be sufficiently low to facilitate removal of the base post 150 from between the two adjacently aligned tiles once the tile-setting material has set. The removal of these posts is most commonly achieved by a person's kicking them or impacting them with a tool, such as a rubber mallet, that will not damage the installed tile. These parameters and steps are so ubiquitously understood by tile installers that further explanation of them is unwarranted.

Depending from the post distal end 154 is at least one cross member 160. As in the example shown, in most configurations, the cross member 160 is integrally formed as an extension of the base post 150. The cross member 160 includes a cross-member distal edge 162 facing away from the tile- supporting platform 115. Moreover, on a cross-member proximal edge 163 generally opposite the cross-member distal edge 162 there is at least one wedge-engaging surface 164. In the particular embodiment shown, the base post 150 and cross member 160 form a substantially T-shaped structure that defines two wedge-engaging surfaces 164. However, alternative configurations are within the scope and contemplation of the invention such as, for example, a dual base post with a cross member that bridges a single wedge-accommodating gap defined between the dual base posts and the cross member.

In the illustrative, non-limiting configuration shown and described, the first breakaway joint JBI is a living hinge HL configured such that the base post 150 is pivotable relative to the tile-supporting platform 115 between post first and second attitudes. In the post first attitude, shown in FIGS. 1 and 2, the base post 150 is substantially coplanar with the tile-supporting platform 115. In more common parlance, the base post 150 "lays flat" along the tile-supporting platform 115. Comparatively, as shown in FIGS. 3 and 4, when in the post second attitude, the base post 150 extends perpendicularly to the tile-supporting platform 115 in a direction upwardly of the platform top side 120. In pivoting between the post first and second attitudes, the base post subtends an angle of substantially 90°. With the benefit of conjunctive reference to FIGS. 1 -4, it is more readily appreciated why the post first and second attitudes are alternatively referred to as, respectively, the "fabrication" and "deployed" attitudes. As molded in an injection mold, for example, the tile-leveling base 100 and wedge 200 are in substantially the configuration shown in FIGS. 1 and 2; that is, with the base post 150 in the post first attitude. To use the tile-leveling base 100, the base post 150 is pivoted to the post second attitude, or, the "deployed attitude."

Referring now to the other principal component, the wedge 200 extends longitudinally along a wedge axis Aw between a wedge heel 210 and a wedge tip 220. A wedge bottom surface 240 and a wedge top surface 260 longitudinally coextend forwardly of the wedge 210 heel and converge to define the wedge tip 220. In the illustrative version depicted, the wedge top surface 260 is undulated in a manner defining a saw tooth or stepped profile, which serves the purpose explained in the summary.

The depicted version of the tile-leveling base and wedge set 10 is configured such that the wedge tip 220 is attached to the cross-member distal edge 162 at a second breakaway joint JB2. The second breakaway joint JB2 facilitates selective separation for use of the wedge 200 from the tile- leveling base 100 without function-defeating damage to either one of the wedge 200 and tile-leveling base 100. As noted in the summary, in an alternative version, the wedge tip 220 may be joined to the tile-leveling base 100 by the second breakaway joint JB2 along the platform periphery 135. Because the scenario in which the wedge tip 220 is attached at the cross-member distal edge 162 is shown, and the relocation of the second breakaway joint JB2 to the platform periphery 135 can be readily envisioned, this latter arrangement is adequately disclosed, supported, and within the scope of the claims appended hereto unless claims language otherwise explicitly excludes it.

FIGS. 5 and 6 show the tile-leveling base 100 and the wedge 200 after they have been separated and are generally situated for use. Tiles are not shown in FIG. 5 so that the relative positions of the tile-leveling base 100 and the wedge 200 can be seen unobstructed. In the side cross- sectional view, however, the tile-leveling base 100 and the wedge 200 are shown in situ relative to first and second tiles ("tile 1" and "tile 2") to be rendered coplanar by the tile-leveling base and wedge set 10 in the general manner explained in the background with respect to existing tiling-leveling bases and wedges.

The benefits of integral fabrication of a tile-leveling base 100 and wedge 200 are several. Integral fabrication facilitates fabrication of a tile-leveling base 100 and appropriately-sized, matching wedge 200 in a single step. At the retailer and user ends, there is assured a matching quantity of bases 100 and wedges 200 on display for sale and on a jobsite. An additional advantage of integral fabrication in a manner described in association with some aspects (e.g., wherein the base post 150 lays flat along the tile-supporting platform 115) is that stacking of plural tile-leveling base and wedge sets 10 is facilitated. FIG. 7 illustratively depicts a plurality of tile-leveling base and wedge sets 10 with the base post 150 of each in the preferred "fabrication attitude," and the wedge 200 of each still attached to its respective tile-leveling base 100. A stack such as that in FIG. 7 could then be packaged for sale.

The foregoing is considered to be illustrative of the principles of the invention. Furthermore, since modifications and changes to various aspects and implementations will occur to those skilled in the art without departing from the scope and spirit of the invention, it is to be understood that the foregoing does not limit the invention as expressed in the appended claims to the exact constructions, implementations and versions shown and described.

Claims

What is claimed is:

1. A tile-leveling base and wedge integrally fabricated and comprising:

a tile-leveling base including a tile-supporting platform with opposed platform top and bottom sides bounded by a platform periphery;

a base post including post proximal and distal ends, the post proximal end being attached to the tile-supporting platform by and at a first breakaway joint with a predetermined tensile strength and a predetermined shear strength;

at least one cross member depending from, and extending perpendicularly to, the post distal end and including a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform top side and (ii) movable into a position in which it is spaced apart by a predetermined distance from, and facing, the platform top side; and

a wedge extending longitudinally along a wedge axis between a wedge heel and a wedge tip, the wedge including a wedge bottom surface and a wedge top surface that coextend longitudinally along the wedge axis and mutually converge to define the wedge tip; wherein, the wedge tip is attached to the cross-member distal edge at a second breakaway joint in order to facilitate selective separation of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base.

2. The tile-leveling base and wedge of claim 1 integrally fabricating by injection molding.

3. The tile-leveling base and wedge of claim 1 wherein the first breakaway joint by which the base post is attached to the tile-supporting platform is a living hinge such that the base post is pivotable relative to the tile-supporting platform between a post first attitude in which the base post is substantially coplanar with the tile-supporting platform and a post second attitude in which the base post extends perpendicularly to the tile-supporting platform in a direction upwardly of the platform top side.

4. The tile-leveling base and wedge of claim 3 wherein the base post and tile-supporting platform are formed at the time of fabrication with the base post in the post first attitude.

A tile-leveling base and wedge integrally fabricated and comprising:

a wedge extending longitudinally along a wedge axis between a wedge heel and a wedge tip, the wedge including a wedge bottom surface and a wedge top surface that coextend longitudinally along the wedge axis and mutually converge to define the wedge tip; wherein, the wedge tip is attached to the tile-leveling base at a second breakaway joint in order to facilitate selective separation of the wedge from the tile-leveling base without function- defeating damage to either one of the wedge and tile-leveling base.

The tile-leveling base and wedge of claim 5 wherein the base post and tile-supporting platform are formed at the time of fabrication with the wedge tip attached to the cross-member distal edge by the second breakaway joint.

The tile-leveling base and wedge of claim 6 wherein the first breakaway joint by which the base post is attached to the tile-supporting platform is a living hinge such that the base post is pivotable relative to the tile-supporting platform between a post first attitude in which the base post extends substantially along the tile-supporting platform and a post second attitude in which the base post extends perpendicularly to the tile-supporting platform in a direction upwardly of the platform top side.

The tile-leveling base and wedge of claim 7 wherein the base post and tile-supporting platform are formed at the time of fabrication with the base post in the post first attitude.

9. The tile-leveling base and wedge of claim 8 integrally fabricating by injection molding.

10. The tile-leveling base and wedge of claim 7 integrally fabricating by injection molding.

11. The tile-leveling base and wedge of claim 6 integrally fabricating by injection molding.

12. A tile-leveling base and wedge integrally fabricated and comprising:

a base post extending perpendicularly to the tile-supporting platform and including post proximal and distal ends, the post proximal end being attached to the tile-supporting platform by and at a first breakaway joint with a predetermined tensile strength and a predetermined shear strength;

at least one cross member depending from, and extending perpendicularly to, the post distal end and including a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is spaced apart by a predetermined distance from, and facing, the platform top side; and

a wedge extending longitudinally along a wedge axis between a wedge heel and a wedge tip, the wedge including a wedge bottom surface and a wedge top surface that coextend longitudinally along the wedge axis and mutually converge to define the wedge tip; wherein, the wedge is attached to the tile-leveling base at a second breakaway joint in order to facilitate selective separation of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base.

13. The tile-leveling base and wedge of claim 12 integrally fabricating by injection molding.

14. The tile-leveling base and wedge of claim 13 wherein the base post and tile-supporting platform are fabricated with the wedge tip attached to the cross-member distal edge at a second breakaway joint in order to facilitate selective separation of the wedge from the tile- leveling base without function-defeating damage to either one of the wedge and tile-leveling base.