Patent Publication Number: US-11643826-B1

Title: Wedge leveling system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of applicant&#39;s co-pending application Ser. No. 29/820,815 filed Dec. 23, 2021, the entire contents of which is hereby expressly incorporated by reference herein. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
     Not Applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention generally relates to a wedge leveling system for laying tile and other surface protective coverings on a surface and more specifically to a tab for use with a wedge to prevent misalignment or lippage of tiles and the like when being laid on the surface. 
     Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
     Many tile and surface protective covering spacing and leveling devices and methods for using the same are known. Examples of such devices and methods are set forth in U.S. Pat. Nos. 7,992,354, 8,671,628 and 8,800,246. These prior art devices and methods for aligning tile and ensuring the edges of adjacent tiles are levelled include levelling devices having a base which is placed below the lower surfaces of two adjacent tiles. The base has a vertical member extending upwardly therefrom and inserted between side edges of the two tiles. The vertical member includes an opening therein and is attached to the base by one or more frangible connections in various positions on the vertical member. The frangible connections are broken or snapped off after the adhesive holding the tiles is set and the wedge is removed, to remove the vertical member from between the tiles. 
     These known devices all use wedges that are inserted through the opening in the vertical member to press against the upper surfaces of the two tiles and push the tiles down against the surface on which they are being laid, to hold the tiles aligned and in place until set. These known devices tend to be expensive to use, have frangible connections in or above the base at different positions in relation to the side edges of the two tiles and do not always provide acceptable and consistent results without the use of additional spacers or other devices or tools. 
     Therefore, there still exists a need in the art for an improved wedge leveling system and the levelling device or tab used with the wedge to maintain the items being attached to a surface in place and in proper alignment, and which is easily broken off at a frangible connection, in the desired position, below the upper surface of the base to provide more consistent and improved results. 
     The wedge leveling system in this document is configured to allow tiles or the like to be easily mounted on opposite sides of the base of the levelling device, with a vertical member held between opposed edges of the tiles. A wedge is then inserted and tightly held in an opening in the vertical element, so as to maintain the tiles or the like in place until set, whereby the wedge may be used to break off an upper protruding portion of the levelling device extending between adjacent tiles or the like or the wedge is removed and the upper protruding portion of the levelling device is easily broken off by kicking or striking with a tool. 
     BRIEF SUMMARY OF THE INVENTION 
     The wedge levelling system will hereinafter be described solely in relation to its use with tiles. However, it is to be understood that the levelling system may be used with substantially any floor, wall or other surface to which a surface coverings or cladding material is to be applied to level tiles. 
     It is a general object of the present invention to provide an improved tile levelling system. It is a more particular object of the present invention to provide a tile leveling system with a levelling device or tab having an opening therein into which a wedge is inserted and held to press on the upper surfaces of adjacent tiles to properly align the edges thereof. 
     It is an object of the wedge leveling system for the tab of the levelling system is preferably made from a thermoplastic material and includes a base and a vertical member extending away from a central area of a top surface of the base. The base of the tab is readily inserted between adjacent tiles with the vertical member extending between opposed edges or ends of the tiles. The base may take any desired shape, but preferably includes side with spaced apart outer ends or feet which are beveled to allow the base to be more easily inserted under adjacent tiles that are being laid and one side with a single tab to form a tri-tab base. 
     It is another object of the wedge leveling system for the tab to includes a first opening formed between leg portions of the vertical member, as well as a second opening on the top portion. The leg portions have rounded lower ends attached to frangible elements held in the bottom of curved openings formed on the top surface of the base. The frangible elements may include small openings therein so as to be easily broken off below the top surface of the base, eliminating separation in the wrong location, after the tiles are set, by either rocking or striking the vertical member. 
     It is an object of the wedge leveling system for the tab to provide a knife edge on the top of the opening in the vertical member to more firmly and securely cooperate with grooves or ribs formed on an angled top surface of a wedge when inserted and held in the opening. The angled top surface is three angles with a relieved area on the sides of the central angle to allow for wedges of different types to be used. 
     It is another object of the wedge leveling system to provide a tile leveling system with a tab having a base with a vertical member having at least one opening therein, which vertical member is connected to the base by spaced legs having frangible lower portions. It is yet another object of the present invention to provide a tile leveling system with a tab that includes a wedge holding opening therein. It is a still further object of the present invention to provide a novel tile leveling system with a tab having an integrated design that is more diverse, easier to use, uses less material to make and which eliminates breaking away of the frangible lower portions in the wrong locations, when compared to available tile levelling devices. 
     It is still another object of the wedge leveling system to provide a levelling system comprising a tab having a three-footed base and a vertical member releasably attached to the base by frangible leg portions held in openings formed on a top surface of the base. The vertical member includes an opening formed between the leg portions and spaced so as to be above two adjacent tiles when the tiles are placed on the base on either side of the vertical member, which extends between adjacent ends or side edges of the tiles. When a wedge is inserted and held in the opening and presses down, the tiles are pushed downwardly toward a surface upon which they are being laid to properly align the edges thereof until the tiles are set. The wedge is then used to break off the vertical member, or the wedge is removed and the vertical member broken off at the frangible portions and removed. 
     It is still another object of the wedge leveling system to provide a levelling system comprising an opening for a leg from the base to fit into the opening between the frangible legs. The central leg is configured with a tab that equates to the thickness of the vertical member so the parts stack in a flat configuration. The tab is also sized to hold within the sides of the opening. The height of the opening is large enough so it does not limit the number of levelers that can be stacked. 
     Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       The objects and features of the wedge leveling system which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, wherein: 
         FIG.  1    is a perspective view of the wedge leveling system in an environment of use. 
         FIG.  2 A  is a front cross-section side perspective view of a preferred embodiment of the tab of the wedge leveling system. 
         FIG.  2 B  is a rear perspective view of a preferred embodiment of the tab of the wedge leveling system. 
         FIG.  3 A  is a front view. 
         FIG.  3 B  is a rear view. 
         FIG.  4 A  is a top plan view. 
         FIG.  4 B  is a bottom plan view. 
         FIG.  5    is sectional view of a frangible connection of a leg of the vertical member to the base taken along line  5 - 5  of  FIG.  4 A . 
         FIG.  6    is a front sectional view taken along line  6 - 6  of  FIG.  4 A . 
         FIG.  7 A  shows two separated tabs. 
         FIG.  7 B  shows two mated tabs. 
         FIG.  8 A  a mated stack of 6 tabs. 
         FIG.  8 B  a side cross-section of a stack of 6 tabs. 
         FIG.  9    is a side elevational view of a first side of  FIG.  1   , the other side being identical thereto. 
         FIG.  10    shows a perspective view of the tab with an alternate version of a wedge. 
         FIG.  11    is an enlarged partial side view of the frangible connection of a leg of the vertical member to the base. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, but is merely representative of various embodiments of the invention. The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. 
     
       
         
           
               
             
               
                   
               
               
                 Item Numbers and Description 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 10 tab 
                 12 base 
               
               
                   
                 13 tile 
                 14 tile 
               
               
                   
                 15 vertical member 
                 16 first opening 
               
               
                   
                 17 wedge 
                 18 second bevel opening 
               
               
                   
                 19 top surface 
                 20 bottom surface 
               
               
                   
                 21 beveled top surfaces 
                 22 openings 
               
               
                   
                 24 leg 
                 26 leg 
               
               
                   
                 28 upper edge 
                 30 opening 
               
               
                   
                 32 opening 
                 34 frangible portion(s) 
               
               
                   
                 35 side lands 
                 36 openings 
               
               
                   
                 38 rounded ends 
                 39 grooves or ribs 
               
               
                   
                 40 upper angled surface 
                 47 indicia 
               
               
                   
                 49 width 
                 48 recess 
               
               
                   
                 50 relief(s) 
                 51 outer edge 
               
               
                   
                 52 single foot 
                 53 taper 
               
               
                   
                 54 side 
                 55 stop 
               
               
                   
                 60 step 
                 61 thickness 
               
               
                   
                 62 fit 
                 63 height 
               
               
                   
                 64 thickness 
                 65 dimension 
               
               
                   
                 66 thickness 
                 67 clearance 
               
               
                   
                   
               
            
           
         
       
     
     Turning now to the drawings,  FIG.  1   , shows a perspective view of the wedge leveling system in an environment of use looking from above, showing two tiles  13  and  14  having a tab of the wedge leveling system with a base  12  inserted under adjacent ends or side edges and a vertical member legs  24  and  26  extending from the base  12  between the ends or side edges of the tiles  13  and  14 . A wedge  17  is inserted and held in an opening formed through the vertical member legs  24  and  25  and presses down on the top surfaces of the two tiles  13  and  14  so as to align the edges and upper surfaces of the tiles  13  and  14 . 
     This figure shows a preferred embodiment of a levelling device or tab  10  having a base  12  for mounting on a surface or substrate (not shown) under adjacent tiles  13 ,  14 , with an adhesive or thinset applied to the surface to be covered and the lower surfaces of the tiles  13 ,  14 . The tab  10  includes a vertical member  15  that is secured to the base  12  with a first opening  16  in the vertical member  15  that is adapted to receive a wedge  17 , as described more fully herein below. The vertical member  15  may also include a second beveled opening  18  on a top portion thereof for easier gripping, handling and insertion under tiles. The second beveled opening  18  reduces material requirement and provides product recognition, such as a logo or identifying symbol or indicia regarding the tile spacing or other information. This top portion is also preferably expanded or thicker to provide additional rigidity when inserting the tab  10 , thereby preventing bending or breaking. 
     As shown more clearly in other figures herein the base  12  includes a top surface  19  and a bottom surface  20 , with spaced apart legs or feet  24 ,  26  with beveled top surfaces  21  on portions of the base  12  that are extending outwardly from either side of the vertical member  15 . Openings  22  are formed in the base between the beveled legs or feet  21 . The openings  22  allow the adhesive or thinset, between the surface being covered and the underside of the tiles  13 ,  14 , to access both sides of the base  12  and provides better adhesion and eliminates bonding gaps that can cause tile breakage. Additionally, the openings  22  and the recess  48  provide lighter weight, less material used and faster mold cooling when fabricating from a plastic, or the like. 
     As best shown in  FIGS.  2 A,  2 B,  3 A and  3 B , the vertical member  15  of the tab  10  has the first opening  16  formed therein between the window or first opening  16  between the two legs  24 ,  26  and an upper edge  28 . The inner or lower ends of the legs  24 ,  26  are held in aligned openings  30 ,  32  that are formed in the top surface  19  of the base approximately along the centerline thereof by reduced width frangible portions  34 . In a preferred embodiment, the openings  30 ,  32  are curved or rounded in profile with optional openings  32 . The bottom surface  20  is flat and has a three-footed base with two feet on one-side that are split with an opening  22  and one foot  52  on the other side of the legs  24  and  26 . The feet have a beveled top surface  21 . 
     At the top of the window or first opening  16  are upper edges  28  and  51  with reliefs  50  at the sides of the upper edge  28 . The relief (s)  50  provide clearance at the sides of the wedge  17 , not shown in these figures. While a second bevel opening  18  and recess  48  is shown these are ornamental or cosmetic styling that can take a variety of styles without changing the functional aspect(s) of the tile leveling system. At least one face of the vertical member  15  can have indicia  47  that indicates the thickness of the legs  24 ,  26  for tile spacing. 
       FIG.  4 A  is a top plan view,  FIG.  4 B  is a bottom plan view,  FIG.  5    is sectional view of a frangible connection of a leg of the vertical member to the base taken along line  5 - 5  of  FIG.  4 A  and  FIG.  6    is a front sectional view taken along line  6 - 6  of  FIG.  4 A . The reduced width frangible portions  34  are formed below rounded ends  38  of the legs  24 ,  26  and have a plurality of openings  36  extending therethrough to allow the frangible portions to be more easily broken off, in the desired position, near the bottoms of curved openings  30 ,  32 , when rocked or sufficient force is applied from either side of the tab  10 , against the vertical member  15 . In this embodiment, two openings  36  are shown but there could be more or less than two openings  36  in the frangible portions  34 . 
     In use, as best shown in the figures, the tab  10  has its base  12  placed on a surface (not shown), such as floor or wall, with the bottom surface  20  of the beveled legs or feet of the base  12  under the lower surface of the tiles  13 ,  14  and with sufficient adhesive or thinset applied to the lower surface of the tiles and the surface to be covered by the tiles to allow the adhesive or thinset to enter the break point area and aid in holding the tab in place. The vertical member  15  is placed so as to extend upwardly between opposed ends or side edges of the tiles, to properly space the tiles apart and to allow the first opening  16  to receive the wedge  17  above the top surfaces of the adjacent tiles. The wedge is forced into the opening  16  until grooves or ribs  39 , formed on an upper angled surface  40  of the wedge  17  to engage with and lock with the upper edge  28  of opening  16 . In one embodiment of the wedge leveling system the upper edge  28  may be formed as a knife edge ( FIG.  3   ) to more securely hold the wedge  17  in position by cooperating with grooves or ribs  39  and, therefore, more firmly press down on the top surfaces of tiles  13 ,  14  so as to align the opposing edges and prevent misalignment or lippage. It is to be understood that sufficient adhesive is placed on the lower surface of the tiles and the surface to be covered, to enable some of the adhesive to enter the openings  22  and flow onto the top surface  19  of the base  12  to aid in holding the base  12  on the supporting surface. 
     After the adhesive holding the tiles and base  12  in place sets, the wedge  17  is either removed or used to aid in breaking the vertical member  15  off in the base  12  by either hitting the wedge or removing the wedge and rocking the vertical member around the frangible portions  34  or hitting the upper end of the vertical member  15 , above the top surface of the tiles, with a hammer or other tool, or by kicking the wedge and/or vertical member  15 . The reduced width frangible portions  34  below the rounded ends  38  of the legs  24 ,  26  on the sides of the window or first opening  16  are broken off along the plurality of openings  36 , essentially at or near the bottom of the rounded openings  30 ,  32 . The rounded openings  30 ,  32  and rounded ends  38 , as well as the openings  36 , allow the frangible portions  34  to be broken off, in the correct location, at or near the bottom of the openings  30 ,  32 , well below the top surface  19  of the base  12 . After the vertical member  15  is broken off and removed, the space between the tiles is filed with grout. The grout also fills in the now empty rounded openings  38  in the base  12  to aid in keeping the base  12  in position underneath the lower surface of the tiles  13 ,  14 . 
     The single foot  52  has a width  49  of the sides  54  that is configured to pass into the window or first opening  16 . At the bottom portion of the single foot  52  have sides that are configured to mate with the insides of the legs  24 ,  26  and the thickness  64  of the base of the tabs  10  can infinitely stack with clearance at the leg  24 ,  26  thickness  61  dimension  65  within the inside height  63  of the window or first opening  16 . A stop(s)  55  limit how far the single foot  52  can pass into the window or first opening  16 . The dimension  65  of the stop  55  is the thickness  66  of the vertical member  15  so adjoining tabs  10  stack in a parallel relationship. At the top of the window or first opening  16  there is an upper edge  28  and  51  that has reliefs  50  for clearance of teeth on the sides of a wedge (not shown in this figure). 
     It, therefore, can be seen that the present wedge leveling system provides an improved levelling system comprising a tab having a base and a vertical member  15  releasably attached to the base  12  by frangible leg  24 ,  26  portions having a plurality of openings  22  formed therein and held in rounded openings formed on the top surface of the base  12 . The vertical member  15  includes an opening spaced so as to be above two adjacent tiles when the tiles are placed on the base on either side of the vertical member  15  which extends between adjacent ends or side edges of the tiles  13 ,  14  to aid in spacing the same. A wedge  17  having an upper angled surface  40  with a number of grooves or ribs  39  that may then be inserted and more securely held in the first opening  16  to press down the tiles  13 ,  14  toward a surface upon which they are being laid to properly align the edges thereof until the tiles  13 ,  14  are set, the wedge  17  removed and the vertical member  15  broken off. 
       FIG.  7 A  shows two separated tabs and  FIG.  7 B  shows two mated tabs where the legs  24 ,  26  of one of the tabs is shows in cross-section. In  FIG.  7 B  the fit  62  engages the sides  54  of the single foot  52  within the inside width  49  of the legs  24 ,  26 .  FIG.  8 A  a mated stack of 6 tabs and  FIG.  8 B  a side cross-section of a stack clearance  67  of at least 6 tabs. The single foot  52  has a width  49  of the sides  54  that is configured to pass into the window or first opening  16 . At the bottom portion of the single foot  52  have tapered  53  sides that are configured to mate with the insides of the legs  24 ,  26  and the thickness  64  of the base of the tabs  10  can infinitely stack with clearance at the leg  24 ,  26  thickness  61  dimension  65  within the inside height  63  of the window or first opening  16 . The stop(s)  55  are limit by a step  60  that limits how far the single foot  52  can pass into the window or first opening  16 . The dimension  65  of the stop  55  is the thickness  66  of the vertical member  15  so adjoining tabs  10  stack in a parallel relationship. At the top of the window or first opening  16  there is an upper edge  28  and  51  that has reliefs  50  for clearance of teeth on the sides of a wedge (not shown in this figure). 
       FIG.  9    is a side elevational view of a first side of  FIG.  1   , the other side being identical thereto and  FIG.  10    shows a perspective view of the tab with an alternate version of a wedge  17 . In these views the tiles  13  and  14  are placed on the sides of the leg  26  and the wedge  17  is inserted between the legs to force the tiles  13 ,  14  onto the top surface  19  of the tile leveler and the bottom of the wedge  17  will level the top surface of the tiles  13 ,  14 . The grooves on ribs  39  engage in the upper edge  28 . While some wedges  17  have grooves that pass across the entire upper surface of the wedge  17  so the three upper edges  28 ,  51  can all engage into a rib or groove, other versions have raised sides  35  on the outside of the wedge. The leveler has relief(s)  50  to allow for clearance of the raised sides  35 . 
       FIG.  11    is an enlarged partial side view of the frangible connection of a leg of the vertical member to the base. After the adhesive sets, the tiles and base  12  in place, the wedge  17  is either removed or used to aid in breaking the vertical member  15  off in the base  12 . The reduced width frangible portions  34  below the rounded ends  38  of the legs  24 ,  26  on the sides of the window or first opening  16  are broken off along the plurality of openings  36 , at or near the bottom of the rounded openings  30 ,  32 . The rounded openings  30 ,  32  and rounded ends  38 , as well as the openings  36 , allow the frangible portions  34  to be broken off, in the correct location, at or near the bottom of the openings  30 ,  32 , below the top surface  19  of the base  12 . 
     Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide for a tile levelling system having an improved tab for insertion between two adjacent tiles so as to both space the tiles apart and cooperate with a wedge inserted into an opening in a vertical member of the tab to align the edges of the two tiles. 
     Thus, specific embodiments of a wedge leveling system have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. 
     SEQUENCE LISTING 
     Not Applicable.