Wedge system

A wedge system for creating a tiled surface includes wedge receivers and wedges. Each wedge receiver has a planar element and a hook extending from the planar element in perpendicular relation. The hook is disposed as a tile spacer between a pair of tiles. The planar element is disposed beneath the tiles. Each wedge has a clamping surface and a ribbed gripping surface orientated in angular relation to one another to meet in an edge with the ribs comprising an arcuate arrangement. In use, the wedge extends through the aperture of the wedge receiver such that the clamping surface is positioned in abutting relation against the tiles and the hook is resiliently deformed to provide for a clamped engagement of the tiles between the clamping surface and the planar element, to provide for substantially coplanar relation of the tiles. Further, the gripping surface grips the wedge receiver to resist withdrawal of the wedge and maintain the clamped engagement until the mortar has cured.

FIELD OF THE INVENTION

The invention relates to the field of tile.

BACKGROUND OF THE INVENTION

It is known to use wedge systems to facilitate the installation of tile.

A known wedge system involves wedges and wedge receivers. Each wedge has a planar surface and a ribbed surface orientated in angular relation to one another to meet in an edge. Each wedge receiver has a planar element and a hook element extending from the planar element in substantially perpendicular relation. The hook element has an aperture defined therein. In use, the tiles are laid in a generally conventional manner. The hook elements are used to space apart the tiles, with the planar elements embedded or laid upon the thin set. Each wedge element is threaded through a respective aperture and pushed forward in the direction of the edge such that the tiles are captured between the planar elements of the wedge receivers and the planar surfaces of the wedges; this causes the tiles to align with one another. The ribbed surface of the wedge receiver provides for a tight and reliable grip. After the mortar has set, the wedges are removed, the hook elements are separated from the planar elements by a mallet and the tiles are grouted in a conventional manner.

SUMMARY OF THE INVENTION

Forming one aspect of the invention is an improved wedge system of the type used with tiles and mortar for creating a tiled surface having an array of the tiles arranged in substantially coplanar side-by-side evenly spaced relation.

The wedge system includes wedge receivers and wedges.

Each wedge receiver has a planar element and a resilient hook element extending from the planar element in substantially perpendicular relation, the hook element having an aperture defined therein and being frangibly connected to the planar element.

Each hook element, in use, is disposed in the manner of a tile spacer between a pair of adjacent tiles in an array of the tiles laid in the mortar, thereby to provide for said substantially even side-by-side spacing of the tiles.

Each planar element, in use, is disposed beneath the pair of adjacent tiles.

Each wedge has a clamping surface and a ribbed gripping surface orientated in angular relation to one another to meet in an edge.

Each wedge, in use, extends through the aperture of a respective receiver such that:the planar surface of the wedge is positioned in abutting relation against the pair of adjacent tiles;the hook element is resiliently deformed, to provide for a clamped engagement of the pair of adjacent tiles between the planar surface of the wedge and the planar element, thereby to provide for said substantially coplanar relation;the gripping surface grips the respective wedge receiver, to resist withdrawal of the wedge from the aperture and maintain the clamped engagement until the mortar has cured.

The improvement comprises an arcuate arrangement of the ribs.

According to another aspect of the invention, the ribs can be shaped such that, in use, when the wedge is inserted through the aperture of a hook element and the hook element is resiliently deformed, an edge of the hook element that presents towards the ribbed surface of the wedge is use, is itself arcuate and nests in a valley defined between adjacent ribs.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Reference is now made toFIG. 1which shows the components of a wedge system20according to an exemplary embodiment of the invention.

The wedge system20will be understood to be of the general type used with tiles and mortar for creating a tiled surface having an array of the tiles arranged in substantially coplanar side-by-side evenly spaced relation and including wedge receivers22and wedges24.

Each wedge receiver has a planar element26and a resilient hook element28extending from the planar element in substantially perpendicular relation, the hook element having an aperture30defined therein and being frangibly connected to the planar element.

Each hook element28, in use, is disposed in the manner of a tile spacer between a pair of adjacent tiles14in an array of the tiles laid in a mortar bed12, thereby to provide for substantially even side-by-side spacing of the tiles. The planar element26from which said each hook element28extends, in use, is disposed beneath the pair of adjacent tiles14, all as shown inFIGS. 5 and 7.

Each wedge has a clamping surface32and a gripping surface34orientated in angular relation to one another to meet in an edge36. At the end of the wedge opposite edge36is a forcing surface52that is disposed at an angle to the clamping surface32.

Each wedge, in use, as shown inFIGS. 6 and 8extends through the aperture of a respective receiver such that:the planar surface of the wedge is positioned in abutting relation against the pair of adjacent tiles;the hook element is resiliently deformed, to provide for a clamped engagement of the pair of adjacent tiles between the planar surface of the wedge and the planar element, thereby to provide for said substantially coplanar relation;the gripping surface grips the respective wedge receiver, to resist withdrawal of the wedge from the aperture and maintain the clamped engagement until the mortar has cured.

After the mortar has cured, the wedges are removed and the hook elements are separated from the planar elements by a mallet, by virtue of the frangible connection therebetween.

Persons of ordinary skill will readily appreciate that all of the above is conventional.

The improved wedge system differs from the prior art by virtue of, inter alia, a gripping surface34defined by a plurality of arcuate ribs38, by a pair of wings or lips on the wedge, opposite the edge36, by an arcuate shape of the forcing surface52and by an angled relationship of the forcing surface52to the clamping surface of about 80°.

More specifically, the arcuate ribs38are shaped such that, in use, when the wedge is inserted through the aperture of a hook element and the hook element is resiliently deformed, an edge40of the hook element that presents towards the ribbed surface of the wedge is use, is itself arcuate and nests in a valley42defined between adjacent ribs38.

The improved wedge system has been found to be relatively easy to use and relatively long-wearing when made of materials similar to those of the prior art.

Whereas prior art wedge systems often require pliers to provide for adequate engagement of the wedges, the wedges in the improved wedge system can be easily installed by hand, with the wedge and wedge receiving pinched between the thumb and forefingers, respectively, of the user. Without intending to be bound by theory, it is believed that the angle of the forcing surface52facilitates hand insertion of the wedge. However, the wedges can also be installed using pliers, if desired.

Further, whereas prior art wedges have a tendency to wear along the edges in use, and typically lose effectiveness after about ten uses, wedges of the present invention have proven useful for up to 100 uses. Without intending to be bound by theory, it is believed that the arcuate arrangement of the ridges provides for the above.

The wings or lips on the wedge facilitate removal of the wedge, when desired, and also increase the surface area of the forcing surface, which, without intending to be bound by theory, may facilitate hand insertion of the wedge.

Other notable areas of improvement in the wedge system shown include steps defined at the leading edge of the wedge, which can be used to clean grout lines, notches defined at the junction of the hook elements and planar elements, to define the frangible connection.

Whereas a specific embodiment is shown inFIGS. 1-10, variations are possible.

For example,FIGS. 11-19show a number of variations of the wedge receiver adapted for use with tiles of differing thickness [the hook elements are taller or shorter, as required] and adapted to produce grout lines of differing thickness [protuberances of differing thicknesses on the hook elements are provided adjacent the notches].

FIGS. 11A-Hare views of a wedge receiver22′ according to another embodiment which is useful for relatively thick tiles and provides for a 1 mm grout line.

FIGS. 12A-Hare views of a wedge receiver22″ similar to that ofFIGS. 11A-Hwhich provides for a 2 mm grout line.

FIGS. 13A-Hare views of a wedge receiver22′″ similar to that ofFIGS. 11A-Hwhich provides for a 3 mm grout line.

FIGS. 14A-Hare views of a wedge receiver22″″ according to another embodiment which is useful for tiles thinner than those ofFIGS. 11-13and provides for a 1 mm grout line.

FIGS. 15A-Hare views of a wedge receiver22′″″ similar to that ofFIGS. 14A-Hwhich provides for a 2 mm grout line.

FIGS. 16A-Hare views of a wedge receiver22″″″ similar to that ofFIGS. 14A-Hwhich provides for a 3 mm grout line.

FIGS. 17A-Hare views of a wedge receiver22′″″″ according to another embodiment which is useful for tiles thinner than those ofFIGS. 14A-Hand which provides for a 1 mm grout line.

FIGS. 18A-Hare views of a wedge receiver22″″″″ similar to that ofFIGS. 17A-Hwhich provides for a 2 mm grout line.

FIGS. 19A-Hare views of a wedge receiver22′″″″″ similar to that ofFIGS. 17A-Hwhich provides for a 3 mm grout line.

As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, numerous changes and modifications may be made to the above-described and other embodiments of the present invention without departing from the spirit of the invention as defined in the claims. Accordingly, this detailed description of embodiments is to be taken in an illustrative, as opposed to a limiting sense, and the claimed invention should be understood as limited only by the accompanying claims, purposively construed.