Abstract:
A tile installation spacer includes a circular disk having opposed, parallel surfaces, and opposed cylindrical first and second spacers extend away from the respective surfaces of the disk. The disk, the first cylindrical spacer, and the second cylinder each have a diameter. The diameter of the disk is greater than the diameter of the first cylindrical spacer and the diameter of the second cylindrical spacer, and the diameter of the first cylindrical spacer is greater than the diameter of the second cylindrical spacer.

Description:
FIELD OF THE INVENTION 
   The present invention relates to tile installation and, more particularly, to tile installation spacers used in the tile installation process and to tile installation methods. 
   BACKGROUND OF THE INVENTION 
   In tiling a surface individual tiles are set onto adhesive applied to the surface of a floor or substrate. The tiles are arranged in a predetermined pattern on the surface and are separated by intertile grout lines or simply grout lines. After the adhesive is sufficiently cured bonding the tiles in place, grout is applied into the grout lines. In the process of setting the individual tiles, spacers are often applied in the grout lines to ensure a uniform spacing between the individual tiles. Typical tile spacers are made of semi-rigid plastic having depths ranging from, for instance, ⅛ to 3/16 of an inch, with spacing widths of between 1/16 of an inch and ⅜ of an inch. For brick, cement block and larger tile forms, larger sizes of spacers, with considerably more depth, are used. 
   The spacers of conventional tile spacers have rectangular or square cross sections. When such a conventional spacer is positioned in a grout line separating adjacent tiles, opposing flat surfaces of the spacer reside in juxtaposition to the opposing confronting edges of the adjacent tiles. If the spacer is twisted or moved during installation or adjustment, it is common for the spacer to act on the confronting edges of the adjacent tiles pushing the opposing tiles apart if the spacer is accidentally twisted or jarred thereby misaligning the adjacent tiles. Also, because conventional spacers have square or rectangular cross sections, such tile spacers are difficult if not impossible to adjust while installed in the grout line without jarring the adjacent tiles out of alignment. Moreover, after a conventional tile spacer is installed in a grout line, it is virtually impossible to make minor adjustments to the adjacent tiles prior to the adhesive curing without causing the tile spacer to shift or twist, which, again, is due principally to the square or rectangular cross section of the spacer applied to the grout line. 
   Given these and other deficiencies in the art of tile spacers, the need for continuing improvement in the art is evident. 
   SUMMARY OF THE INVENTION 
   It is an object of the invention to provide a tile installation spacer that is easy to make, easy to install into an intertile grout line between adjacent tiles, that can be moved or otherwise adjusted relative to adjacent tiles while installed in the grout line without risk of pushing the adjacent tiles out of alignment if the tile installation spacer is twisted or rotated relative to the adjacent tiles, which is low in cost, and which offers different modes of use to accommodate grout lines of varying width. 
   According to the principle of the invention, a tile installation spacer consists of a disk including opposed parallel first and second surfaces and a center, a circular, circumferential edge encircling the center of the disk, a diameter extending through the center of the disk meeting at the circular, circumferential edge at each end, and a uniform thickness from the first surface to the second surface. A first cylindrical spacer has a proximal end affixed to the first surface of the disk and extends away from the first surface of the disk to a distal end, a center, a circular, circumferential outer surface encircling the center of the first cylindrical spacer, and a uniform diameter from the proximal end to the distal end of the first cylindrical spacer extending through the center of the first cylindrical spacer meeting at the circular, circumferential outer surface of the first cylindrical spacer. A second cylindrical spacer has a proximal end affixed to the second surface of the disk and extends away from the second surface of the disk to a distal end, a center, a circular, circumferential outer surface encircling the center of the second cylindrical spacer, and a uniform diameter from the proximal end to the distal end of the second cylindrical spacer extending through the center of the second cylindrical spacer meeting at the circular, circumferential outer surface of the second cylindrical spacer. The diameter of the disk is greater than the diameter of the first cylindrical spacer and the diameter of the second cylindrical spacer, and the diameter of the first cylindrical spacer is greater than the diameter of the second cylindrical spacer. The first cylindrical spacer has a depth extending outwardly from the first surface of the disk which is a significant fraction of a depth of a tile to be spaced thereby and the first diameter of the first cylindrical spacer is equal to a width of an intertile grout line which is intended to separate tiles to be spaced thereby, and the circular, and the circular, circumferential outer surface of the first cylindrical spacer allows the first cylindrical spacer to rotate in the intertile grout line separating tiles to be spaced thereby. The second cylindrical spacer has a depth extending outwardly from the second surface of the disk which is a significant fraction of a depth of a tile to be spaced thereby and the second diameter of the second cylindrical spacer is equal to a width of an intertile grout line which is intended to separate tiles to be spaced thereby, and the circular, circumferential outer surface of the second cylindrical spacer allows the second cylindrical spacer to rotate in the intertile grout line separating tiles to be spaced thereby. The tile installation spacer defines an axis extending through the centers of the disk and the first and second cylindrical spacers from the distal ends of the first and second spacers about which the disk and the first and second cylindrical spacers are symmetrical. The thickness of the disk is different from the diameter of the first cylindrical spacer and the second cylindrical spacer. The disk has a depth extending circumferentially outward from the circular, cylindrical outer surface of the first cylindrical spacer which is a significant fraction of a depth of a tile to be spaced thereby and the thickness of the disk is equal to a width of an intertile grout line which is intended to separate tiles to be spaced thereby, and the circular, circumferential edge of the disk allows the disk to rotate in the intertile grout line separating tiles to be spaced thereby. The disk, the first cylindrical spacer, and the second cylindrical spacer are formed of a single piece of semi-rigid material. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring to the drawings: 
       FIG. 1  is a top perspective view of a tile installation spacer constructed and arranged in accordance with the principle of the invention; 
       FIG. 2  is a bottom perspective view of the tile installation spacer of  FIG. 1 ; 
       FIG. 3  is a side elevational view of the tile installation spacer of  FIG. 1 ; 
       FIG. 4  is a perspective view of a plurality tile installation spacers in accordance with the principle of the invention in use setting tiles; 
       FIG. 5  is a side elevational view of the tile installation spacer of  FIG. 1  shown as it would appear installed in a first orientation in the intertile grout line between opposed tiles; 
       FIG. 6  is a top plan view of the installation of  FIG. 5 ; 
       FIG. 7  is a side elevational view of the tile installation spacer of  FIG. 1  shown as it would appear installed in a second orientation in the intertile grout line between opposed tiles; 
       FIG. 8  is a top plan view of the installation of  FIG. 7 ; 
       FIG. 9  is a side elevational view of the tile installation spacer of  FIG. 1  shown as it would appear installed in a third orientation in the intertile grout line between opposed tiles; and 
       FIG. 10  is a top plan view of the installation of  FIG. 9 . 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   Turning now to the drawings, in which like reference characters indicate corresponding elements throughout the several views, attention is directed in relevant part to  FIGS. 1-3  in which there is seen a tile installation spacer  20  constructed and arranged in accordance with the principle of the invention including a disk  21  having opposed parallel surfaces  22  and  23  and a center, and a circular, circumferential edge  24  encircling the center of disk  21 . Referenced in  FIG. 3 , disk  21  has a diameter D 1  extending through the center of disk  21  meeting at circular, circumferential edge  24  at each end, and a uniform thickness T from surface  22  to surface  23 . Disk  21  is broad and circular, as illustrated. Tile installation spacer  20  is formed with opposed cylindrical spacers  30  and  40 . Cylindrical spacer  30  has a proximal end  31  affixed to surface  22  of disk  21  and extends away from surface  22  of disk  21  to an opposed distal end  32 . Cylindrical spacer  30  has a center, a circular, circumferential outer surface  33  encircling the center of cylindrical spacer  30  extending from proximal end  32  to distal end  33 , and, as referenced in  FIG. 3 , a uniform diameter D 2  from proximal end  31  to distal end  32  of cylindrical spacer  30  extending through the center of cylindrical spacer  30  meeting at outer surface  33  of cylindrical spacer  30 . Cylindrical spacer  40  has a proximal end  41  affixed to surface  23  of disk  21  and extends away from surface  23  of disk  21  to an opposed distal end  42 . Cylindrical spacer  40  has a center, a circular, circumferential outer surface  43  encircling the center of cylindrical spacer  40  extending from proximal end  42  to distal end  43 , and, as referenced in  FIG. 3 , a uniform diameter D 3  from proximal end  41  to distal end  42  of cylindrical spacer  40  extending through the center of cylindrical spacer  40  meeting at outer surface  43  of cylindrical spacer  40 . 
   Tile installation spacer  20  defines an axis A extending through and defining the centers of disk  21 , cylindrical spacer  30 , and cylindrical spacer  40 , about which disk  21  and cylindrical spacers  30  and  40  are symmetrical. Diameter D 1  of disk  21  is greater than diameter D 2  of cylindrical spacer  30 . Diameter D 1  of disk  21  is also greater than diameter D 3  of cylindrical spacer  40 . Diameter D 2  of cylindrical spacer  30  is greater than diameter D 3  of cylindrical spacer  40 . Moreover, thickness T of disk  21  is less than diameter D 3  of cylindrical spacer  40 . Tile installation spacer  20  is, according to a preferred embodiment, are made of a unitary piece of semi-rigid material, such as plastic, elastomeric material, or the like. 
   Tile installation spacers  20  constructed and arranged in accordance with the principle of the invention are used in the installation of tiles to space the tiles apart to form uniform intertile grout lines between the tiles  50 . Tile installation spacer  20  is useful in three ways, the first of which is illustrated in  FIGS. 5 and 6 , the second of which is illustrated in  FIGS. 7 and 8 , and the third of which is illustrated in  FIGS. 9 and 10 . 
   In a first mode of use of tile installation spacer  20  as illustrated in  FIG. 5 , opposed tiles  50  are set onto adhesive  52  applied to a supporting substrate  53  leaving an intertile grout line  51  therebetween. In this operation, width W 1  of intertile grout line  51  is equal to diameter D 3  (referenced only in  FIG. 3 ) of cylindrical spacer  40 . As such, tile installation spacer  20  is taken up, such as by hand, and maneuvered to insert cylindrical spacer  40  into intertile grout line  51  between tiles  50  bringing surface  23  into resting engagement against the upper or outer faces of opposed tiles  50  as illustrated in  FIG. 5 . Diameter D 1  of disk  21  is substantially greater than width W 1  of intertile grout line  51  to ensure surface  23  of disk  21  rests on the upper or outer faces of tiles  50  in the installation of cylindrical spacer  40  in intertile grout line  51 , maintaining cylindrical spacer  40  in intertile grout line  51  and preventing tile installation spacer  20  from tipping over during this installation process. Cylindrical spacer  40  has a depth extending outwardly from surface  23  of disk  21  from proximal end  41  at surface  23  of disk  21  to distal end  42  which is a significant fraction of the depth of each tile  50  to be spaced thereby, and diameter D 3  of cylindrical spacer  40  is equal to width W 1  of intertile grout line  51  which is intended to separate tiles  50  to be spaced thereby. As adhesive  52  cures, cylindrical spacer  40  positioned in intertile grout line  51  maintains the spacing between tiles  50  formed by intertile grout line  51 . 
   Circular, circumferential outer surface  43  of cylindrical spacer  40  allows cylindrical spacer  40 , and thus the whole of tile installation spacer  20 , to rotate in clockwise and counterclockwise directions about axis A in intertile grout line  51  separating tiles  50  to be spaced thereby as indicated by the double arrowed line B in FIG.  6 , such as in an adjustment of tile installation spacer  20  along grout line  51 , or perhaps as the opposed edges of tiles  50  forming intertile grout line  51  act on circular, circumferential outer surface  43  of cylindrical spacer  40  as tiles  50  are shifted back and forth in the setting of tiles  50 , in accordance with the principle of the invention. Because diameter D 3  of cylindrical spacer  40  is uniform from proximal end  41  of cylindrical spacer  40  to distal end  42  of cylindrical spacer  40 , the width of cylindrical spacer  40  as defined by diameter D 3  does not change relative to grout line  51  and relative to the confronting edges of opposing tiles  50  as cylindrical spacer  40  rotates in grout line  51  and the width W 1  of intertile grout line  51 , therefore, does not change when tiles  50  shift and act on circular, circumferential outer surface  43  of cylindrical spacer  40  causing tile installation spacer  20  to rotate relative to tiles  50 , or otherwise if cylindrical spacer  40  is rotated in grout line  51  through the rotation of tile installation spacer  20  or the adjustment of tile installation spacer  20  along grout line  51 . Accordingly, the cylindrical shape of cylindrical spacer  40 , as herein described, prevents cylindrical spacer  40  from acting on the adjacent tiles  50  in response to rotation of cylindrical spacer  40  in grout line  51 . After adhesive  52  is sufficiently cured, tile installation spacer  20  may be removed and grout applied into intertile grout line  51 . As a matter of illustration,  FIG. 4  is a perspective view of a plurality of tile installation spacers  20  used in this first mode of operation and shown installed in intertile grout lines  51  between tiles  50  to maintain the spacing between tiles  50  provided by intertile grout lines  51 . 
   In a second mode of use of tile installation spacer  20  as illustrated in  FIG. 7 , opposed tiles  50  are set onto adhesive  52  applied to a supporting substrate  53  leaving an intertile grout line  55  therebetween. In this operation, width W 2  of intertile grout line  55  is equal to diameter D 2  (referenced only in  FIG. 3 ) of cylindrical spacer  30 . Width W 2  of intertile grout line  55  in  FIG. 7  is greater than width W 1  of intertile grout line  51  in  FIGS. 5 and 6 . As such, tile installation spacer  20  is taken up, such as by hand, and maneuvered to insert cylindrical spacer  30  into intertile grout line  55  between tiles  50  bringing surface  22  into resting engagement against the upper or outer faces of opposed tiles  50  as illustrated in  FIG. 7 , maintaining cylindrical spacer  30  in intertile grout line  55  and preventing tile installation spacer  20  from tipping over during this installation process. Diameter D 1  of disk  21  is substantially greater than width W 2  of intertile grout line  55  to ensure surface  22  of disk  21  rests on the upper or outer faces of tiles  50  in the installation of cylindrical spacer  30  in intertile grout line  55 . Cylindrical spacer  30  has a depth extending outwardly from surface  22  of disk  21  from proximal end  31  at surface  22  of disk  21  to distal end  32  which is a significant fraction of the depth of each tile  50  to be spaced thereby, and diameter D 2  of cylindrical spacer  30  is equal to width W 2  of intertile grout line  55  which is intended to separate tiles  50  to be spaced thereby. As adhesive  52  cures, cylindrical spacer  30  positioned in intertile grout line  55  maintains the spacing between tiles  50  formed by intertile grout line  55 . 
   Circular, circumferential outer surface  33  of cylindrical spacer  30  allows cylindrical spacer  30 , and thus the whole of tile installation spacer  20 , to rotate in clockwise and counterclockwise directions about axis A in intertile grout line  55  separating tiles  50  to be spaced thereby as indicated by the double arrowed line C in  FIG. 8 , such as in an adjustment of tile installation spacer  20  along grout line  55 , or perhaps as the opposed edges of tiles  50  forming intertile grout line  55  act on circular, circumferential outer surface  33  of cylindrical spacer  30  as tiles  50  are shifted back and forth in the setting of tiles  50 , in accordance with the principle of the invention. Because diameter D 2  of cylindrical spacer  30  is uniform from proximal end  31  of cylindrical spacer  30  to distal end  32  of cylindrical spacer  30 , the width of cylindrical spacer  30  as defined by diameter D 2  does not change relative to grout line  55  and relative to the confronting edges of opposing tiles  50  as cylindrical spacer  30  rotates in grout line  51  and the width W 2  of intertile grout line  55 , therefore, does not change when tiles  50  shift and act on circular, circumferential outer surface  33  of cylindrical spacer  30  causing tile installation spacer  20  to rotate relative to tiles  50 , or otherwise if cylindrical spacer  30  is rotated in grout line  55  through the rotation of tile installation spacer  20  or the adjustment of tile installation spacer  20  along grout line  55 . Accordingly, the cylindrical shape of cylindrical spacer  30 , as herein described, prevents cylindrical spacer  30  from acting on the adjacent tiles  50  in response to rotation of cylindrical spacer  30  in grout line  55 . After adhesive  52  is sufficiently cured, tile installation spacer  20  may be removed and grout applied into intertile grout line  55 . A plurality of tile installation spacers  20  may be used in the second mode of operation like in the illustration of  FIG. 4 . 
   As previously mentioned, thickness T of disk  21  illustrated in  FIG. 3  is less than diameter D 3  of cylindrical spacer  40 , and may be used in the setting of tiles. In a third mode of use of tile installation spacer  20  as illustrated in  FIG. 9 , opposed tiles  50  are set onto adhesive  52  applied to a supporting substrate  53  leaving an intertile grout line  56  therebetween. In this operation, width W 3  of intertile grout line  56  is equal to thickness T (referenced only in  FIG. 3 ) disk  21 . Width W 3  of intertile grout line  55  in  FIG. 9  is lesser than width W 1  of intertile grout line  51  in  FIGS. 5 and 6 . As such, tile installation spacer  20  is taken up, such as by hand, and maneuvered to insert circular, circumferential outer edge  24  of disk  21  into intertile grout line  56  between tiles  50  bringing circular, cylindrical outer surface  33  of cylindrical spacer  30  into resting engagement against the upper or outer face of one of the opposed tiles  50  as illustrated in  FIG. 9 . Disk  21  has a depth extending circumferentially outward from circular, cylindrical outer surface  33  of cylindrical spacer  30  to circular, cylindrical outer edge  24  which is a significant fraction of the depth of each tile  50  to be spaced thereby, and thickness T of disk  21  is equal to width W 3  of intertile grout line  56  which is intended to separate tiles  50  to be spaced thereby. As adhesive  52  cures, disk  21  positioned in intertile grout line  56  maintains the spacing between tiles  50  formed by intertile grout line  56 . Circular, circumferential outer edge  24  of disk  21  in intertile grout line  56  and circular, circumferential outer surface  33  of cylindrical spacer  30  resting on one of the opposed tiles  50  allows disk  21 , and this the whole of tile installation spacer  20 , to rotate in clockwise and counterclockwise directions in and along intertile grout line  56  separating tiles  50  to be spaced thereby to move tile installation spacer  20  in reciprocal directions along and relative to intertile grout line  56  as indicated by the double arrowed line D in  FIG. 10  to allow for adjusting of tile installation spacer  20  as needed. Because thickness T of disk  21  is uniform from circular, circumferential outer surface  33  of cylindrical spacer  30  to circular, cylindrical outer edge  24  of disk  21 , width W 3  of intertile grout line  56  does not change as tile installation spacer  20  is rotated or otherwise rolled along and relative to intertile grout line  56 . After adhesive  52  is sufficiently cured, tile installation spacer  20  may be removed and grout applied into intertile grout line  55 . A plurality of tile installation spacers  20  may be used in the third mode of operation like in the illustration of  FIG. 4 . 
   The dimensions of the thickness T of disk  21 , diameter D 2  of cylindrical spacer  30 , and diameter D 3  of cylindrical spacer  40  are different relative to each other as herein disclosed thereby providing at least three modes of operation of tile installation spacer  20 , namely, to allow tile installation spacer  20  to be used in at least three different tiling operations involving three different grout line widths including one corresponding to thickness T of disk  21 , one corresponding to diameter D 2  of cylindrical spacer  30 , and one corresponding to diameter D 3  of cylindrical spacer  40 . The dimension of thickness T of disk  21 , diameter D 2  of cylindrical spacer  30 , and diameter D 3  of cylindrical spacer  40  are each, therefore, different from one another, and each can each be provided to define a particular dimension and depth to meet any required grout line width and depth. 
   The invention has been described above with reference to a preferred embodiment. However, those skilled in the art will recognize that changes and modifications may be made to the embodiment without departing from the nature and scope of the invention. Various changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof. 
   Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: