Abstract:
A tile adhesive removal system having a handle, or tool, and one or more removable tips. When applying ceramic tiles, one should remove any excess adhesive in the channel between an existing tile and a tile currently under application. A properly-sized tip is selected for a particular channel width, and is removably attached to the handle. The handle and tip together may remove any excess adhesive from the channel between tiles, and then may be easily cleaned for use in applying the next tile. The size of the handle and tip together is large enough so that the cleaning process is relatively simple for the user. The removal system may have an orienting element, so that the tip is not inserted upside down, and may have an attachment element, such as one or more bumps that engage one or more corresponding detents.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention is directed to ceramic tiling, and more particularly to a tool used to clean out and level the adhesive between ceramic tiles during installation.  
         [0003]     2. Description of the Related Art  
         [0004]     During the installation of tile, a time-consuming and inconvenient step is the cleaning out of excess adhesive from the grout joints after the tile is beaten in. Tile installation typically proceeds as follows. Tile adhesive is keyed into the backing surface with the straight side of a trowel, and is then combed to a uniform depth using the notched side of the trowel held at a consistent 45° angle. It is good practice to clean the edges next to adjacent tile of excess adhesive with a margin trowel to prevent too much adhesive squeeze into the grout joint. The final step in setting the tile is to beat in the tile with a beating block and rubber mallet. After beat in, the tile surface is cleaned with a tile sponge.  
         [0005]     Since adhesive typically is squeezed into the grout joints during beat in and may fill the joints unevenly and in some places to excess, the excess adhesive should be cleaned out from the grout joints when the tile surface is being cleaned. A common method of removing excess adhesive from grout joints is to run a “spacer” along the joint. Spacers are a type of known device for uniformly spacing tiles during installation to establish uniform grout joints. Although they are commonly used by tile professionals for excess adhesive removal, they are not specifically made for this purpose. A typical spacer is made from a non-porous material such as plastic or rubber, and resembles a “+”-sign. Prong widths of 1/16 inch, ⅛ inch, 3/16 inch and ¼ inch are typical. Once the adhesive dries, the spacers in place between the tiles are removed, and grout is applied over the dried adhesive in the region between the tiles.  
         [0006]     When removing excess adhesive with a spacer, the spacer is run down the grout joints at an incline so that the spacer does not reach the bottom of the channel between the tiles. It is preferable to leave some adhesive in the region between the tiles to increase the bonding strength of the tiles. The spacer collects the excess adhesive down to a depth that typically and disadvantageously is neither precisely known nor constant, leaving a channel of adhesive that irregularly fills a portion of the grout joint between the tiles.  
         [0007]     There are several drawbacks to using a spacer to remove the excess adhesive. First, the spacers themselves are relatively small, which makes them difficult to handle and can cause discomfort to the fingers. Second, after a spacer has been used to remove the excess adhesive, it is difficult to clean because of its small size, and as a result typically ends up being thrown out. This is wasteful. Third, if a tiling job entails a large number of tiles, a large number of spacers may be used for cleaning out the excess adhesive between the tiles, and may therefore be thrown out. This may prove expensive, and the large number of spacers that are used only for cleaning may unnecessarily increase the cost of the job.  
         [0008]     Accordingly, there exists a need for a tool that is comfortable to use, can remove the excess adhesive from the channel between adjacent ceramic tiles during installation, can be cleaned easily for reuse, and can easily accommodate a variety of installation spacings between the tiles.  
       BRIEF SUMMARY OF THE INVENTION  
       [0009]     One object of the present embodiment is a tool for leveling and cleaning out tile adhesive in a grout joint between adjacent tiles, comprising a handle; and a tip extending from the handle, the tip comprising an alignment surface; and a member projecting from the alignment surface and generally established about a first plane with a width within the plane substantially equal to the width of the grout joint, and a height within the first plane for extending into the grout joint a predetermined distance from the alignment surface.  
         [0010]     Another embodiment is a removable tip for a tool for leveling and cleaning out tile adhesive in a grout joint between adjacent tiles, comprising a connector for removably coupling the tip to the tool; an alignment surface distally spaced from the connector; and a member projecting distally from the alignment surface and generally established about a plane with a width within the plane substantially equal to the width of the grout joint, and a height within the plane for extending into the grout joint a predetermined distance from the alignment surface.  
         [0011]     Another embodiment is a system for removing excess adhesive in a channel between adjacent tiles, comprising a handle having an attachment end; and at least one removable tip that attaches to the attachment end of the handle, the at least one removable tip having a ridge that is insertable into the channel between adjacent tiles.  
         [0012]     Another embodiment is a removable tip for a tool for leveling and cleaning out tile adhesive in a grout joint between adjacent tiles, comprising means for connecting the tip to the tool; means for aligning the tip to the grout joint; and means for dispersing excess adhesive as the tool is translated along the grout joint. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0013]      FIG. 1  is a top view drawing of a tile adhesive removal tool with a handle and removable tip.  
         [0014]      FIG. 2  is a top view drawing of a handle for the tile adhesive removal tool of  FIG. 1 .  
         [0015]      FIG. 3  is a left side view drawing of the handle of  FIG. 2 .  
         [0016]      FIG. 4  is a proximal end view drawing of the handle of  FIGS. 2 and 3 .  
         [0017]      FIG. 5  is a side view drawing of a removable tip for the tile adhesive removal tool of  FIG. 1 .  
         [0018]      FIG. 6  is a top view drawing of the removable tip of  FIG. 5 .  
         [0019]      FIG. 7  is a distal end view drawing of the removable tip of  FIGS. 5 and 6 .  
         [0020]      FIG. 8  is a plan drawing of the removable tip of  FIGS. 5-7 .  
         [0021]      FIG. 9  is a cross-sectional drawing of a tile adhesive removal tool used in a relatively shallow, wide grout joint.  
         [0022]      FIG. 10  is a cross-sectional drawing of a tile adhesive removal tool used in a relatively deep, narrow grout joint.  
         [0023]      FIG. 11  is a cross-sectional drawing of a tile adhesive removal tool that uses the body of the tool to set the orientation angle at which the tool is held.  
         [0024]      FIG. 12  is a cross-sectional drawing of a tile adhesive removal tool with multiple tips.  
         [0025]      FIG. 13  is a plan drawing of a tip that has bent back portions for setting the angle at which the tool is held.  
         [0026]      FIG. 14  is a left side view drawing of an alternate embodiment of a handle.  
         [0027]      FIG. 15  is a proximal end view drawing of the handle of  FIG. 14 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]     A grout joint clean out and tile adhesive leveling tool has a tip and a handle. The tip has an alignment surface for slidably resting upon the faces of adjacent tiles, and a projecting member having a width substantially equal to the width of the grout joint, and a height for extending into the grout joint a predetermined distance from the alignment surface. When the tool is moved along the grout joint, the projecting member redistributes and/or removes excess tile adhesive from the grout joint so as to leave a uniform layer of adhesive of a particular desired thickness in the bottom of the grout joint. Preferably the tip is designed for repeated use and is made of a slick, non-porous, rigid and durable material so as to slide easily over tile without absorbing the excess tile adhesive, to withstand the stresses to which it is subject during normal use on multiple occasions, and to withstand water and other solvents with which it might come into contact during normal use and cleaning on multiple occasions. Alternatively, the tip may be made of any desired material or combination of materials to achieve any of a variety of different performance objectives; illustratively, the tip may be semi-porous and impregnated with water or other solvent for aiding in the redistribution and/or removal of adhesive, and may be made for limited use. The handle may have any configuration and size suitable for the user, and may connect to the tip via a shaft of any length or configuration as may be desired for convenience and ease of use. The tip and handle may be a unitary structure such as, for example, a single molded plastic piece, or may be an integrated structure of the same or different materials. In an integrated structure, the tip may be permanently secured to the handle with an adhesive, weld, or in any other desired manner, or the tip may be removably attached to the handle with a mechanical or any other type of temporary connector so that it can be removed and replaced. Preferably the connector is operable by the user so that the tip may be changed by the user as needed.  
         [0029]     For a particular tiling scheme, in which the spacing between tiles is known, the user selects a tip of a size that corresponds to the spacing, attaches it to the handle (for a tool having changeable tips), and uses the handle and tip to remove the excess adhesive in the channel between adjacent tiles. After a pass along the channel, the excess adhesive captured by the tip is easily removed from the handle and tip, and the handle and tip are easily cleaned for use in application of the next tile. The combined size of the handle and tip is preferably large enough so that the handle and tip may be easily washed off together in a container of water, which is difficult to do with a common spacer.  
         [0030]     An example of a tile adhesive removal tool  10  is shown in  FIG. 1 . A tip  2  is attached to a handle  1 . The tip has a ridge that is sized to fit in the channel between adjacent tiles. During use, a user grips the handle, inserts the ridge of the tip into one end of the channel, and guides the tool along the channel to remove any excess adhesive in the channel. As drawn in  FIG. 1 , the tip  2  is removable from the handle  1 , but it may alternatively be integrated into the handle  1 .  
         [0031]     The handle  1  of  FIG. 1  is shown in more detail in  FIGS. 2-4 .  FIG. 2  shows a top view,  FIG. 3  shows a left side view, and  FIG. 4  shows a proximal end view. The handle  1  has a body  14  that is gripped by the user in a grip region  15 , which may optionally have grooves, bumps or ridges for enhancing the grip of the user on the handle  1 . Alternatively, the grip region  15  may be flat.  
         [0032]     Adjacent to the grip region  15  at the proximal end of the handle  1  is a storage compartment cover  16 . The cover  16  may unscrew from the handle  1  to allow the user to store parts or extra tips inside the handle  1 . Alternatively, the cover  16  may be secured by any applicable method, such as by being hinged or having a friction fit.  
         [0033]     Opposite the storage end of the handle  1  is the attachment end  17 , to which a removable tip may be attached. The removable tip fits securely onto the attachment end  17  of the handle  1 , and is held in place by a friction fit, a mechanical device, or in any other desired manner. Preferably, a friction fit is used in conjunction with a pair of notches  18  on the attachment end  17 , which engage a pair of detents on the removable tip. The user presses the removable tip on the attachment end  17  of the tool until the detents engage the notches  18 . The tip may be removed by gripping and pulling it off the attachment end  17  of the tool  17 .  
         [0034]     The attachment end  17  of the handle  1  may optionally have an orientation ridge  19  on one side, so that the removable tip may be attached with only one particular orientation. As drawn in  FIGS. 2-4 , the orientation ridge  19  protrudes along the attachment end  17  in a relatively narrow channel, and engages a slot in the removable tip, so that the tip is prevented from being attached upside down. Alternatively, the orientation ridge  19  may be located off-center with respect to the attachment end  17 . As a further alternative, the orientation ridge  19  may be one or more bumps on the attachment end  17 , rather than a true ridge.  
         [0035]      FIGS. 5-8  show an exemplary embodiment of a removable tip  2  in various views.  FIG. 5  shows a side view,  FIG. 6  shows a top view,  FIG. 7  shows a distal end view, and  FIG. 8  shows a plan view of the underside of the removable tip  2 . The removable tip  2  has a main body  25 , which attaches the removable tip  2  to the attachment end  17  of the handle  1 . Protruding from the main body  25  is an insertable ridge  27 , which during use extends into the groove or channel between tiles and redistributes or removes any excess adhesive. As shown in  FIGS. 5-8 , the insertable ridge  27  may optionally be tapered in one or more dimensions, preferably decreasing in size away from the main body  25 . The end  28  of the insertable ridge  27  may be flat, as drawn in  FIGS. 5-8 , or may be rounded in one or more dimensions.  
         [0036]     The main body  25  attaches to the handle  1 , and in the exemplary embodiment of  FIGS. 5-8 , has a pair of resilient arms  24  located on opposite sides of the main body  25 . At one end of each arm  24  is a bump  26 , which engages a notch  18  on the handle  1  when the removable tip  20  is attached. One of ordinary skill in the art will appreciate that any suitable method of attachment may be used to attach the removable tip to the tool; the bumps and detents shown in  FIGS. 2-8  are merely exemplary.  
         [0037]     If the tip is designed asymmetrically, it may be desirable to have element that prevents the tip from being installed upside-down. The tool of  FIGS. 2-8  uses an orientation ridge  19  on the handle  1 , which fits into an alignment groove  30  on the removable tip  2 . If the user attempts to attach the tip with the incorrect orientation, the orientation ridge  19  prevents the placement of the removable tip  2  onto the attachment end  17  of the handle  1 . Although the alignment groove  30  is shown as being centered on one face of the removable tip  2 , it may also be off-center. Alternatively, more than one groove and ridge may be used. As a further alternative, one or more bumps on the tool may be used, rather than a ridge. As yet another alternative, the ridge may be on the tip, rather than the tool, and the channel may be on the tool, rather than the tip. One of ordinary skill in the art will appreciate that the embodiment may use any other suitable method of preventing the insertion of the removable tip with an incorrect orientation.  
         [0038]     Because a variety of tiles with different thickness are available and because a variety of grout joint thickness are desired by installers, tips may be made available in a variety of different dimensions.  FIG. 9  shows an installation in which relatively thin tiles  82  and  84  are installed on backing  88  with a relatively wide grout joint between them. The use of a tool with a relatively wide but shallowly projecting tip  80  is appropriate. Element  86  is the adhesive in the grout joint. On the other hand,  FIG. 10  shows an installation in which relatively thick tiles  92  and  94  are installed on backing  98  with a relatively narrow grout joint between them. The use of a tool with a relatively narrow but deeply projecting tip  90  is appropriate. Element  96  is the adhesive in the grout joint.  
         [0039]     The removable tip may optionally have a label  29  that indicates the width of the insertable ridge  27 , which is the top-to-bottom dimension of the insertable ridge  27  in  FIG. 6 . By reading the label  29 , the user knows the size of the insertable ridge  27 , and therefore knows which removable tip to use for a given spacing between tiles. The exemplary label  29  in  FIG. 6  reads “⅛ SPACE”, which indicates that the width of the insertable ridge is ⅛ inch. The tool  10  may be sold with a set of removable tips, each with a different dimension, so that a variety of tiling schemes may be accommodated. Typical dimensions include, but are not limited to 1/16 inch, ⅛ inch, 3/16 inch and ¼ inch.  
         [0040]     The removable tip  25  may be tapered or rounded in any of the dimensions, in addition to the optional taper of the insertable ridge  27 . The tapered regions  31  reduce the overall size of the removable tip, and therefore use less material, resulting in a less expensive product. Furthermore, the tapered region  31  may make easier the cleaning of the tip, which occurs after use for a particular tile.  
         [0041]     In the tool of  FIGS. 1-8 , the alignment surface of the tool  1  is preferably either the beveled surface  31  or the beveled surface  33 , depending on the orientation of the tool  1  relative to the direction of travel. The tool  1  preferably is angled away from normal in the direction of travel, and the beveled surface  31  or  33  provides some tactile feedback when the tip  20  is properly angled. However, many different techniques may be used to facilitate the proper angling of the tip.  FIG. 11  shows a simplified and less flexible implementation in which the proper angle between tool axis  110  and tile surface  116  is maintained by flat surface  114  of main body  112 , thereby establishing the proper penetration distance of projecting member  118 .  FIG. 12  shows a dual-tip embodiment in which the proper angle between primary tool axis  120  and a parallel secondary tool axis  121  and tile surface  126  is maintained by the cooperative effect of spaced-apart surfaces  124  and  125  of main body  122 , thereby establishing the proper penetration distance of projecting members  127  and  128 .  FIG. 13  shows yet another technique in which the main body of tip  130  is not slab-like as in  FIG. 7 , but rather has bent back portions  132  and  134  with respective edges  133  and  135 . The edges  133  and  135  are angled so that when the tool to which the tip  130  is connected is properly angled, the edges  133  and  135  are in full contact with the surfaces of adjacent tiles defining the grout joint, thereby establishing the proper penetration distance of projecting member  136 .  
         [0042]     Preferably measures are taken to prevent twisting of the tip in the grout joint. When a single tip is used, the length of the projecting member is preferably greater than the width thereof. In  FIG. 11 , for example, the projecting member  118  is shown from the side or along its length. The width (not shown) of the projecting member preferably is equal to or less than the length. On the other hand, the length of the projecting members  127  and  128  of the tip shown in  FIG. 12  may be less than the width thereof, since twisting is prevented by using two projecting members  127  and  128  in a spaced-apart relationship.  
         [0043]     The tip of  FIG. 12  has a further advantage. In the implement shown in  FIG. 12 , the height of the leading projecting member  127  is less than the height of the trailing projecting member  128 . When the tool is in use, the projecting member  127  may remove and/or redistribute great excesses of adhesive from the grout joint without causing too much drag on the tool, while the projecting member  128  is at the proper height to level the adhesive at the right depth even while removing and/or redistributing lesser excesses of adhesive. However, the height may be established for other purposes. Illustratively, the height of the projecting members of the tip may be the same for redundancy.  
         [0044]      FIGS. 14 and 15  show an alternate embodiment of a handle  140 . The handle  140  has various features that may enhance a user&#39;s grip on the tool, including depressions  141  and  142  and holes  143 ,  144 ,  145 ,  146  and  147 . The holes preferably do not extend all the way through the handle  140 , although alternatively they may extend fully through the handle  140 . In addition to enhancing the grip, the features may reduce the overall volume of the handle  140 , thereby using less material for its production and reducing the overall cost of the tool.  
         [0045]     The description of the invention and its applications as set forth herein is illustrative and is not intended to limit the scope of the invention. Variations and modifications of the embodiments disclosed herein are possible, and practical alternatives to and equivalents of the various elements of the embodiments would be understood to those of ordinary skill in the art upon study of this patent document. These and other variations and modifications of the embodiments disclosed herein may be made without departing from the scope and spirit of the invention.