Device for leveling and aligning tile and method for leveling and aligning tiles

A device for leveling and aligning tiles and method for leveling and aligning tiles are disclosed. In one embodiment, the leveling device includes a body and two spaced and parallel strip members extending transversely from the body. Each of the spaced and parallel strip members extend to the front and rear of the body. Two opposing lateral open windows are formed in the body. A breakaway section is defined along the body. A wedge device is provided for penetrating one or more of the two opposing lateral open windows and exerting a force on the tiles for leveling them relative to each other.

TECHNICAL FIELD OF THE INVENTION

This invention relates, in general, to tile installation and, in particular to a device for leveling and aligning tiles and properly spacing tiles during the installation thereof.

BACKGROUND OF THE INVENTION

Tile has become a popular decorative and functional article for use in floors, walls, countertops, and the like. Both professional tile installers and do-it-yourselfers spend a great deal of time aligning and leveling tiles as they are being placed on a substrate's surface. Proper alignment and leveling of each tile is important for a number of reasons. Improper installation can cause the need for tiles to be replaced in order to prevent a spacing error from propagating across the substrate, aesthetic reasons, and in some instances, safety concerns. A need exists for a device for leveling and aligning tiles and properly spacing tiles.

SUMMARY OF THE INVENTION

It would be advantageous to achieve a device for leveling and aligning tiles and properly spacing tiles. It would also be desirable to enable a mechanical-based solution that furnishes an inexpensive tool that assists professional tile installers and do-it-yourselfers. To better address one or more of these concerns, in one aspect of the invention, a tile leveling device and a wedge device for use with tiles are disclosed. In one embodiment, the leveling device includes a body and two spaced and parallel strip members extending transversely from the body. Each of the spaced and parallel strip members extend to the front and rear of the body. Two opposing lateral open windows are formed in the body. A breakaway section is defined along the body.

In one implementation, a wedge device includes a backstop member and a pair of members extending from the backstop member. Each of pair of members includes a tapered surface configured to penetrate the lateral open windows and exerting force against tiles, thereby pressing the tiles against the first and second strip members in order to level and align.

In another embodiment, the leveling device includes an inverted U-shaped body with an I-shaped base orthogonally coupled thereto. An open window is located within the U-shaped body between stems thereof. The I-shaped base has four bars extending transversely from the inverted U-shaped body and that extend upwards toward the inverted U-shaped body in an arcuate fashion to define respective four points of contact for two, three, and four tiles. Two breakaway sections are respectively defined along the spaced stems of the inverted U-shaped body at the I-shaped bar. In another implementation, a wedge device includes an oversized backstop member and a wedge member extending from the oversized backstop member. These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

DETAILED DESCRIPTION OF THE INVENTION

Referring initially toFIGS. 1A,1B, and2, therein is depicted one embodiment of a tile leveling device that is schematically illustrated and generally designated10. The tile leveling device10and a wedge device12are utilized, in combination, to align and level two, three, or four tiles, for example. The leveling device10includes a body14and spaced and parallel strip members16,18extending transversely from the body14. Each of the spaced and parallel strip members extend to the front F and rear R of the body14. Lateral open windows20,22having upper edges21,23are formed in the body14and sized to accept a member having a tapered surface configured to penetrate the respective lateral open windows20,22and exert force thereunder. A breakaway section24is defined along the body14. The breakaway section24may be a frangible section of the body14of reduced thickness that would promote the breakaway, and thus, separation of the body14. An upper bump26and a lower bump28extend horizontally across the body14. The upper bump being larger and more pronounced to provide lifting power. A spacing pad30is integral with the body14and may vary in thickness depending on the application. The spacing pad30contributes to furnishing a combination of vertical leveling and joint spacing within a single product. Moreover, the spacing pad30, which may be more generally a spacer, is configured to position the tiles a predetermined distance apart depending on the application.

The spaced and parallel strip members16,18provide four points of contact32,34,36,38for lift of tiles, while still establishing space for maximum mortar penetration between the spaced and parallel strip members16,18. As shown, the spaced and parallel strip members16, have an arcuate form wherein the spaced and parallel strip members16,18curve upwards from the junction with the body14to the four points of contact32,34,36,38. That is, the spaced and parallel strip members16,18define convex curvatures40,42that are flexible and compressible for tile installation during a leveling and alignment of a tile. The convex curvatures40,42also ensure that tiles of varying thicknesses may be leveled and aligned. In fact, in the corner embodiment, four tiles having four varying thicknesses may be leveled and aligned by way of the flexibility and compressibility of the convex curvatures40,42of the strip members16,18.

The wedge device12includes a backstop member50and two extension members, depicted as wedge members52,54extending from the backstop member50. The backstop member provides a push area for fingers or a thumb and an enhanced sized that furnishes more leverage during use. Each of the wedge members52,54include respective tapered surfaces56,58configured to penetrate the lateral open windows20,22and exert force against the tiles by pressing the tiles against the strip members16,18. Teeth60,62are located along the tapered surfaces56,58in order to latch onto the respective upper edges21,23of the opposing lateral open windows21,23. In operation, the teeth60,62prevent the respective wedge members52,54from slipping out of the open windows20,22during penetration thereof. As will be appreciated, the wedge device12may penetrate the leveling device from the front F or rear R.

Referring now toFIGS. 3 through 5, the tile leveling device may be utilized with two tiles70,72(FIG. 3), three tiles (FIG. 4)74,76,78, or four tiles80,82,84,86(FIG. 5) for installation on a substrate, subsurface, or other surface, which is indicated by the letter S. By way of example, in the two tile installation, the tile70is positioned over the front portions of the strip members16,18. The tile70has a lower surface88opposite an upper surface90, wherein the lower surface88faces the strip members16,18and the subsurface S. The upper surface90is farther from the strip members16,18than the lower surface88and faces away from the strip members16,18. The second tile72is similarly situated over the rear portions of the strip members16,18and includes a lower surface92and an upper surface94.

Accordingly, a single leveling device10and wedge device12may be utilized to install, align, and level between two and four tiles. The use of the wedge device12having two extension members and the two lateral open windows provides for utilization at corner tiles; thereby offering improved efficiency. More particularly, using one leveling device for a corner improves efficiency and minimizes the number of leveling devices required to complete a job. Additionally, as previously discussed, the arcuate portions of the parallel strip members compress and flatten to accommodate different thicknesses of tiles to provide a level surface. In fact, the leveling device and wedge device presented herein may simultaneously accommodate between two and four different thicknesses of tiles.

Referring now toFIGS. 6 through 9, one example of installation is shown wherein the tile leveling device10is placed such that one end of the tile72sits on the rear portions of the parallel strip members16,18and the tile abuts the body14of the leveling device. Such an installation methodology may be used for any of the configurations shown inFIGS. 3 through 5, for example. By way of illustration, therefore, this example is for the two tile application ofFIG. 3. The adjacent tile70sits on the other side of the body14and across the front portions of the parallel strip members16,18. The extension members, namely wedge members52,54of the wedge device12are then inserted in the respective lateral open windows20,22. The backstop member50is then pushed, thereby driving the wedge members52,54to penetrate the respective lateral open windows20,22.

In one embodiment, the wedge device offers an advantage over individual wedges as the backstop member provides a wider or broader surface to push. In particular, as shown inFIG. 8, a thumb or finger may be used to drive the wedge device12into the leveling device10. The ease of push advantage translates into a more powerful lift because of the more evenly distribution of the lifting surface. Therefore, the leveling device10and wedge device combination provide improved performance, both quantitatively and qualitatively. With respect to the former, the lateral open windows in combination the wedge device permit use at corners increasing efficiency and reducing the number of leveling and aligning operations, which leads to faster installation using fewer leveling devices. With respect to the latter, the improved contact surface provided by the backstop member minimizes the stress and strain on the fingers and thumbs.

Additionally, the design of the wedge device discourages the tiles from pivoting by providing two points of contact with each tile edge. By way of example, on a 12 inch by 12 inch tile, a traditional installation system would require two spacers for each side, for a total of eight spacers, in order to stabilize the edges and prevent pivoting. Using the teachings presented herein, four leveling devices10may be used and the optimal eight points of contact would be maintained.

Continuing with the description ofFIGS. 6 through 9, in one implementation, as these wedge-shaped extension members are continually pushed through the lateral open windows20,22due to the increasing thickness of the wedge members52,54, the action causes the lower surfaces88,92of each of the tiles70,72to be compressed downward pressing the strip members16,18beneath the tiles70,72toward the subsurface S, on which is located mortar M for bonding the tiles70,72to the subsurface S. As a result, the tiles70,72are aligned and leveled. The spacing between the tiles is controlled by the thickness of the body and, in one embodiment, the presence of the spacing pad30, which may more generally be a spacer. Once the tiles70,72are set, the wedge device12may be removed and the body14is broken off by kicking or applying force to the side of the wedge device12such that the body14is severed at the breakaway section24. As shown inFIG. 9, the application of force by a boot, breaks the body at break B at the breakaway section24. In the illustrated implementation, the breakaway section24is positioned such that it is located between the surfaces88,90,92,94of the tiles70,72. That is, the breakaway section24is located at a height within the thickness of the installed tiles. In this position, the breakaway section24is not exposed to any adhesive that may be used to adhere the tiles to the subsurface S, which may be a floor or wall, for example.

Referring now toFIG. 10, an alternative embodiment of the tile leveling device10includes the body and the spaced and parallel strip members16,18extending transversely from the body14. In this embodiment, opposing lateral closed windows100,102are formed in the body14with each of the opposing lateral closed windows100,102sized to accept a wedge device having wedge members including a tapered surface configured to penetrate the respective lateral closed windows100,102and exert force against multiple tiles pressing the tiles against the strip members16,18. Additionally, the breakaway section24is defined along the body14. By way of further example, a further embodiment is possible, wherein the leveling device10would include a lateral open window and a lateral closed window.

Referring toFIGS. 11A,11B, and12, in one embodiment of a tile leveling device110and tile combination with a wedge device112, the tile leveling device110includes an inverted U-shaped body114defining an open window116between two stems118,120of the inverted U-shaped body114. An I-shaped base122is orthogonally coupled to the inverted U-shaped body114such that four spaced bars124,126,128,130extend transversely from the inverted U-shaped body114. In particular, the spaced bars124,126extend to the front, F, of the inverted U-shaped body114and the spaced bars128,130extend to the rear, R, of the inverted U-shaped body114. Each of the bars124,126,128,130extends upward toward the inverted U-shaped body in an arcuate fashion to define respective four points of contact132,134,136,138for two, three, and four tiles.

Two breakaway sections140,142are defined along the respective two stems118,120of the inverted U-shaped body114. Additionally, as shown, a notch144is formed between the bars124,126and a notch146is formed between the bars128,130. The open window116includes an upper edge148. An open span150is proximally interposed between the breakaway sections140,142and the open span150forms a portion of the open window116. Spacing pads, such as spacing pad152, may be utilized to position the tiles a predetermined distance apart, depending on the application.

The wedge device112includes an oversized backstop member160. A wedge member162extends from the oversized backstop member160and includes a tapered surface164that is configured to penetrate the open window116and exert force against two, three, or four tiles pressing the tiles against the bars124,126,128,130. The breakaway sections140,142are located where the ends of the stems118,120of the inverted U-shaped body114contact the I-shaped base122. Teeth166are positioned along the tapered surface164in order to latch onto the upper edge148of the open window116.

In operation, the leveling device110may be used to align two, three or four tiles and operation is similar to leveling device10and wedge device12, as previously presented. Similar to the leveling device presented inFIG. 5, in a four-tile embodiment, each tile has corner-to-subfloor contact due to the notches that provide space for mortar contact therein. Similarly, in a two-tile implementation, for example, each tile has edge-to-subfloor contact due to the notches. More particularly, the tapered surface164penetrates the open window116contacting the upper edge148thereof and exerting force against both tiles pressing the tiles against the bars124,126,128,130, wherein breakaway sections140,142are located beyond the undersurfaces of the tiles in a direction away from the bars124,126,128,130. As previously discussed, the arcuate portions of the parallel strip members compress and flatten to accommodate different thicknesses of tiles to provide a level surface. In fact, the leveling device and wedge device presented herein may simultaneously accommodate between two and four different thicknesses of tiles.

Referring now toFIGS. 13 and 14, a tile leveling device200for use with a locking subassembly202are presented. As shown, the tile leveling device includes a shaft204and spaced and parallel strip members206,208extend transversely from the shaft204. The locking subassembly202is configured to traverse the shaft and exert force against the tiles by pressing the tiles against the parallel strip members, similar to the functionality described in previous embodiments. Each of the spaced and parallel strip members extend to the front and rear of the shaft204. A frangible breakaway section206is defined along the shaft204. A spacing pad207, which may be similar to spacing pad30, may be integral with the shaft204and may vary in thickness depending on the application. The spaced and parallel strip members206,208provide four points of contact210,212,214,216for lift of tiles, while still establishing space for maximum mortar penetration between the spaced and parallel strip members206,208. Convex curvatures218,220ensure that the tiles of varying thicknesses may be leveled and aligned, including the alignment of up to four tiles of varying thickness.

In operation, once the tiles are properly positioned, the locking subassembly202is secured in its place above the tiles and prevented from moving along the shaft204before being driven down to compress the tiles. The shaft204may include a locking surface222, such as a “zip tie” to enable movement along the shaft204by the locking subassembly202in only one direction, i.e., toward the tiles.