Patent Publication Number: US-11649647-B2

Title: System and device for leveling and aligning tiles and method for use of same

Description:
PRIORITY STATEMENT &amp; CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 17/667,738 entitled “System and Device for Leveling and Aligning Tiles and Method for Use of Same” and filed on Feb. 9, 2022, in the names of Clinton D. Bunch et al., now U.S. Pat. No. 11,408,186 and issued on Aug. 9, 2022; which claims priority from U.S. Patent Application Ser. No. 63/147,554 entitled “System and Device for Leveling and Aligning Tiles and Method for Use of Same” filed on Feb. 9, 2021, in the names of Clinton D. Bunch et al.; which are hereby incorporated by reference, in entirety, for all purposes. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     This invention relates, in general, to tile installation and, in particular, to a system and 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&#39;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 system and device for leveling and aligning tiles and a method for leveling and aligning tiles are disclosed. In one embodiment of the tile leveling system, a tile leveling device includes an upright body having a head and base at opposite ends thereof. The base and the upright body are integral prior to a frangible separation. The tile leveling device is selectively threaded through a line-of-sight opening of a wedge device for use in an operational configuration. These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which: 
         FIG.  1    is a perspective view of one embodiment of a tile leveling device and one embodiment of a wedge device, which together forma tile leveling system, according to the teachings presented herein; 
         FIG.  2    is a perspective view of one operational configuration of the tile leveling system with the tile leveling device and the wedge device of  FIG.  1   ; 
         FIG.  3    is a top plan view of the tile leveling device presented in  FIG.  1   ; 
         FIG.  4    is a side view of the tile leveling device presented in  FIG.  1   , which has left-right symmetry; 
         FIG.  5    is a bottom plan view of the tile leveling device presented in  FIG.  1   ; 
         FIG.  6    is a perspective view taken from a bottom front angle of the tile leveling device presented in  FIG.  1   ; 
         FIG.  7    is a front elevation view of the tile leveling device presented in  FIG.  1   , which has front-rear symmetry; 
         FIG.  8    is a perspective view taken from a front bottom angle of the tile leveling device presented in  FIG.  1   ; 
         FIG.  9    is a top plan view, with certain features shown with dashed lines, of the wedge device presented in  FIG.  1   ; 
         FIG.  10    is a bottom plan view, with certain features shown with dashed lines, of the wedge device presented in  FIG.  1   ; 
         FIG.  11    is a top plan view of the wedge device presented in  FIG.  1   ; 
         FIG.  12    is a side elevation view, with certain features shown with dashed lines, of the wedge device presented in  FIG.  1   ; 
         FIG.  13    is a side elevation view of the wedge device presented in  FIG.  1   , in cross-section along lines  13 - 13  of  FIG.  9   ; 
         FIG.  14    is a front elevation view of the wedge device presented in  FIG.  1   , in cross-section along lines  14 - 14  of  FIG.  12   ; 
         FIG.  15    is a rear elevation view of the wedge device presented in  FIG.  1   ; 
         FIG.  16 A  is a top plan view of the tile leveling system presented in  FIG.  2    in a first configuration; 
         FIG.  16 B  is a top plan view of the tile leveling system presented in  FIG.  2    in a second configuration; 
         FIG.  16 C  is a top plan view of the tile leveling system presented in  FIG.  2    in a third configuration; 
         FIG.  17 A  is a top plan view of another embodiment of the tile leveling system presented in  FIG.  2    in a first configuration; 
         FIG.  17 B  is a top plan view of another embodiment of the tile leveling system presented in  FIG.  2    in a second configuration; 
         FIG.  17 C  is a top plan view of another embodiment of the tile leveling system presented in  FIG.  2    in a third configuration; 
         FIG.  18    is a top plan view of the tile leveling system presented in  FIG.  1    and  FIG.  2    being utilized in a two tile installation; 
         FIG.  19    is a top plan view of the tile leveling system presented in  FIG.  1    and  FIG.  2    being utilized in a three tile installation; 
         FIG.  20    is a top plan view of the tile leveling system presented in  FIG.  1    and  FIG.  2    being utilized in a four tile installation; 
         FIG.  21 A  is a side elevation view, in partial cross-section, of the tile leveling system of  FIG.  1    and  FIG.  2    being utilized to install tile at a first stage of installation; 
         FIG.  21 B  is a side elevation view, in partial cross-section, of the tile leveling system of  FIG.  1    and  FIG.  2    being utilized to install tile at a second stage of installation; 
         FIG.  21 C  is a side elevation view, in partial cross-section, of the tile leveling system of  FIG.  1    and  FIG.  2    being utilized to install tile at a third stage of installation; 
         FIG.  21 D  is a side elevation view, in partial cross-section, of the tile leveling system of  FIG.  1    and  FIG.  2    being utilized to install tile at a fourth stage of installation; 
         FIG.  21 E  is a side elevation view, in partial cross-section, of the tile leveling system of  FIG.  1    and  FIG.  2    being utilized to install tile at a fifth stage of installation; 
         FIG.  21 F  is a side elevation view, in partial cross-section, of the tile leveling system of  FIG.  1    and  FIG.  2    being utilized to install tile at a sixth stage of installation; 
         FIG.  22    is a perspective view taken from a bottom front angle of another embodiment of the tile leveling device, according to the teachings presented herein; and 
         FIG.  23    is a perspective view taken from a bottom front angle of still another embodiment of the tile leveling device, according to the teachings presented herein. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention. 
     Referring initially to  FIG.  1    through  FIG.  15   , therein is depicted one embodiment of a tile leveling system that is schematically illustrated and generally designated  10 . The tile leveling system  10 , which includes a tile leveling device  14  and a wedge device  16 , is utilized to align and level two, three, or four tiles, for example. The tile leveling device  14  includes an upright body  18  having an upper end  20  and a lower end  22 , a front  24 , and a rear  26  with a perimeter  28  therearound. In some applications, where the upright body  18  is cylindrical or includes a cylindrical portion, the perimeter  28  may be a circumference or include a circumference. A central vertical axis  30  extends through the upright body  18 . A head  32  is coupled to the upper end  20  of the upright body  18 . In one embodiment, the head  32  has a guide surface  34 , including a left guide surface portion  36  and a right guide surface portion  38 . The guide surface  34  faces the direction of the lower end  22  of the upright body  18 . Each of the left guide surface portion  36  and the right guide surface portion  38  may include a sharpened surface having a contact edge to provide enhanced contact with the wedge device  16 . As shown, the head  32  includes a front  40  and a rear  42  with a head height H 1 , a head width W 1 , and a head depth D 1 . The upright body  18  in combination with the head height H 1 , the head width W 1 , and the head depth D 1  provide subterminal opposition surfaces  44  in which the palmar surfaces of a thumb and index finger can hold at least one of the upright body  18  and the head  32  therebetween for manipulation of the tile leveling device  14  during use of the tile leveling system  10 . 
     In some embodiments, the tile leveling device may also include a spacer  46  extending from the front  24  of the upright body  18 . The spacer  46  is configured to position a tile at a predetermined distance from the tile leveling device  14 . Similarly, the tile leveling device  14  may include a spacer  48  extending from the rear  26  of the upright body  18  in order to position a tile at a predetermined distance. It should be appreciated that the spacers  46 ,  48  may act as spacing pads that are integral with the upright body  18  and may vary in thickness depending on the application. The spacers  46 ,  48  contribute to furnishing a combination of vertical leveling and joint spacing within a single product. 
     In some embodiments, the tile leveling device  14  includes respective clipped corners  50 ,  52  at an intersection of the head  32  and the guide surface  34 , which may be transverse, with clipped corner  50  being positioned at the left guide surface portion  36  and the clipped corner  52  being positioned at the right guide surface portion  38 . The clipped corners  50 ,  52  improve and provide clearance between the head  32  and the wedge device  16  during the interconnection of the tile leveling device  14  and the wedge device  16 , to better accommodate multiple tile thicknesses and keep the entire assembly as compact as possible. The tile leveling device  14  may also include a flared portion  54  proximate the lower end  22  of the upright body  18 . In some embodiments, the flared portion  54  provides greater strength to the upright body  18  while spreading the tension during operation across a frangible breakaway section  94 . The flared portion  54  may have a triangular appearance with a tapered edge. In this manner, the flared portion  54  provides additional strength while having a form factor which does not interfere with the selective interconnectivity of the tile leveling device  14  and the wedge device  16 . The combination of the additional strength and increased spread of tension provides sufficient support as tiles are manipulated through the installation process. Further, this combination of the additional strength and increase spread of tension provides sufficient support for manipulating tiles of different thicknesses during the tile installation process. 
     As shown, in the illustrated embodiment, a base  60  is orthogonally coupled to the lower end  22  of the upright body  18 . The base  60  includes an upper surface  62  and a lower surface  64  extending from a midline  66  of the base  60  to the front  24  of the upright body  18  and the rear  26  of the upright body  18 . The upper surface  62  and the lower surface  64  intersect at a front edge  68 , which is positioned at the front  24  of the upright body  18 . Similarly, the upper surface  62  and the lower surface  64  intersect at a rear edge  70 , which is positioned at the rear  26  of the upright body  18 . 
     As shown, the base  60  includes a thickness Ti greater at the midline  66  than a thickness  12  at the front edge  68  or a thickness  13  at the rear edge  70 , providing, in some embodiments, a sharp insertion point. In one embodiment, the variation in thickness arises from the upper surface  62  being a substantially horizontal surface and the lower surface  64  being a non-linear surface that is tapered from the midline  66  toward each of the front edge  68  and the rear edge  70 . With this arrangement, each of the front edge  68  and the rear edge  70  provide an entry wedge, such as an entry wedge  72  and an entry wedge  74 , sized for easier insertion between a tile and subsurface. 
     The base  60  may have any shape, including circular shapes, rectangular shapes, triangular shapes, or typographical shapes, like the letter “H” or “I.” In one embodiment, the base  60  is an I-shaped base. Spaced and parallel strip members  76 ,  78  provide four points of contact  80 ,  82 ,  84 ,  86  for lift of tiles, while still establishing space for maximum mortar penetration between the spaced and parallel strip members  76 ,  78 . Further, it should be appreciated that the base  60  may include base elements such as holes, openings, notches, grooves, and combinations thereof, for example. As shown, in one embodiment, the base  60  includes notches  88 ,  90 . 
     In some embodiments, a base-to-body coupling  92  positioned at the intersection of the upright body  18  and the base  60  includes the frangible breakaway section  94 . The upright body  18  and the base  60  are integral prior to frangible separation such that the frangible breakaway section  94 , upon breaking, frangibly separates the upright body  18  and the base  60 . The frangible breakaway section  94  may be a frangible section of the upright body  18  of reduced thickness that would promote the breakaway, and thus, separation of the upright body  18 . The frangible breakaway section  94  may include one or more frangible breakaway section portions and may include features like small holes, tapered edges, and the like. By way of example, the base  60  may include a channel  96  at the base-to-body coupling  92 . The channel  96  lowers the breakoff point at or below a top of the base  60 . 
     In some embodiments, the wedge device  16  includes a backstop member  100  and a body member  102 . As shown, the body member  102  may have an attachment end  104 , a penetrating edge  106 , a top  108 , a bottom  110 , and sidewalls  109 ,  111 . The attachment end  104  is coupled to the backstop member  100  and the penetration edge  106  may be configured to penetrate the tile leveling device  14  at the guide surface  34 . The body member  102  may include an inclined plane  112  tapering from the attachment end  104  to the penetrating edge  106 . The body member  102  includes a longitudinal axis  114  from the attachment edge  104  to the penetrating edge  106 . As depicted, the longitudinal axis  114  has a longitudinal length L 1 . 
     A line-of-sight opening  116  extends along the longitudinal axis  114  and intersects the longitudinal length L 1  with the line-of-sight opening  116  having an opening length L 2  and an opening width W 2 . The line of sight opening  116  is configured to be penetrated by the tile leveling device  14 . In one implementation, the opening length L 2  is greater than the head width W 1  and the opening width W 2  is greater than the head depth D 1 . In this manner, the opening width W 2  accommodates the perimeter  28  to permit rotational movement of the upright body  18  of the tile leveling device  14  within the line-of-sight opening  116 . With this configuration, the tile leveling device  14  and the wedge device  16  may be interconnected by insertion then rotation, as shown by arrows A I , A R . The line-of-sight opening  116  also provides visibility through the body member  102  from the top  108  to the bottom  110 . The inclined plane  112  may include a toothed surface  118 . In operation, teeth forming the toothed surface  118  prevent the wedge device  16  from slipping out of contact with the left guide surface portion  36  and the right guide surface portion  38  forming the guide surface  34  during penetration thereof. As will be appreciated, the wedge device  16  may penetrate the tile leveling device  14  from the front  24  or rear  26 . 
     In one embodiment, the body member  102  of the wedge device  16  includes a beveled edge  120  at an intersection of the bottom  110  and the line-of-sight opening  116 . The beveled edge  120  and the flared portion  54  work with the clipped corners  50 ,  52 , providing greater strength while accommodating multiple tile thicknesses as it allows the lower end  22  of the upright body  18  of the tile leveling device  14  to start at a higher point and disperse the applied pressure. In particular, the clipped corners  50 ,  52  improve and provide clearance between the head  32  and the beveled edge  120  when the tile leveling device  14  is selectively threaded through the line-of-sight opening  116  of the wedge device  16  as will be discussed in further detail hereinbelow. Further, as shown, the body member  102  at the penetrating edge  106  includes a closed end member  122  forming a closed loop  124  that provides a slotted wedge design. When the penetrating edge  106  fully engages the tile leveling device  14 , the closed end member  122  interconnects inclined plane members  126 ,  128  of the inclined plane  112  to strengthen side-to-side placement of tiles by ensuring more uniformed distribution of forces of the tiles and ensuring that the inclined plane members  126 ,  128  are in the same vertical plane. For additional support, a base extension member  130  circumscribes the sidewalls  109 ,  111  and the backstop member  100 . The base extension member  130  may also ensure more uniform distribution of forces on the tiles and ensure the inclined plane members  126 ,  128  stay within the same vertical plane, particularly in instances where three or four tiles are being installed. It should be appreciated that although a particular wedge device, the wedge device  16 , is shown, the tile leveling system, including the tile leveling device  14 , may be utilized with other types of wedge devices. By way of example and not by way of limitation, the wedge device  16  may have an open end rather than a closed end member at the penetrating edge, as will be presented below. In the open end embodiments, in some implementations, the open end defines a double headed wedge. 
     Referring now to  FIGS.  16 A,  16 B, and  16 C , the tile leveling system  10  includes an operational configuration wherein the tile leveling device  14  is selectively threaded through the line-of-sight opening  116  of the wedge device  16 . As seen best in  FIG.  16 A , the head  32  of the tile leveling device  14  is inserted through the line-of-sight opening  116  of the wedge device  16  proximate the penetrating edge  106  with the head width W 1  aligned with the opening length L 2 . That is, as seen best in  FIG.  16 A , the line-of-sight opening  116  of the wedge device  16  may be placed over and the head  32  of the tile leveling device  14 . Then, as best seen in  FIG.  16 B , the head  32  is rotated, as shown by arrow R, such that guide surface  34  is positioned perpendicular to the inclined plane  112  for contact with the inclined plane  112 . Following the selective positioning of the tile leveling device  14  within the wedge device  16 , as best seen in  FIG.  16 C , the tile leveling device  10  is ready for leveling operations. 
     Referring now to  FIGS.  17 A,  17 B, and  17 C , in another embodiment, the tile leveling system  10  includes an operational configuration wherein the tile leveling device  14  is selectively threaded through the line-of-sight opening  116  of the wedge device  16 . As seen best in  FIG.  17 A , the head  32  of the tile leveling device  14  is inserted through the line-of-sight opening  116  of the wedge device  16  proximate the penetrating edge  106  with the head width W 1  aligned with the opening length L 2 . Then, as best seen in  FIG.  17 B , the head  32  is rotated, as shown by arrow R, such that guide surface  34  is positioned perpendicular to the inclined plane  112  for contact with the inclined plane  112 . Following the selective positioning of the tile leveling device  14  within the wedge device  16 , as best seen in  FIG.  17 C , the tile leveling device  10  is ready for leveling operations. 
     Referring now to  FIG.  18    through  FIG.  20   , the tile leveling device  10  may be utilized with two tiles TL 1 , TL 2  ( FIG.  18   ), three tiles TL 1 , TL 2 , TL 3  ( FIG.  19   ) or four tiles TL 1 , TL 2 , TL 3 , TL 4  ( FIG.  20   ) for installation on a substrate, subsurface, or other surface, which is indicated by the letter S having mortar M, as shown in  FIGS.  21 A through  21 F . Grout lines G are located between each of the adjacent tiles. By way of example, with reference to  FIG.  21 A  through  FIG.  21 F , in the two-tile installation, the tile TL 1  is positioned over the front portions of the spaced and parallel strip members  76 ,  78 . The tile TL 1  has a lower surface opposite an upper surface, wherein the lower surface faces the spaced and parallel strip members  76 ,  78  and the subsurface S. The grout line G is the space between the two tiles TL 1 , TL 2 . The upper surface is farther from the spaced and parallel strip members  76 ,  78  than the lower surface and faces away from the spaced and parallel strip members  76 ,  78 . The second tile TL 2  is similarly situated over the rear portions of the spaced and parallel strip members  76 ,  78  and includes a lower surface and an upper surface. 
     As shown, the tile TL 1  is over the base  60  to the front  24  of the upright body  18 . As mentioned, the tile TL 1  has a lower surface opposite an upper surface. The tile TL 1  has contact with mortar M at the notch  88  (as best shown in  FIG.  18   ), wherein the lower surface faces the base  60  and the upper surface is farther from the base  60  than the lower surface. Similarly, the tile TL 2  is over the base  16  at the rear  26  of the upright body  18 . The tile TL 2  has similar surfaces to the tile TL 1  with mortar M at the notch  90  (as best shown in  FIG.  18   ). The frangible breakaway section  94  may be located between the lower surface and the upper surface of the tile TL 1  and similarly positioned with respect to the tile TL 2 . 
     In operation, an individual may place the tile leveling system  10 , including the tile leveling device  14 , on the subsurface S and then position the mortar M and desired number of tiles. As best seen in  FIG.  21 A , the entry edge  72  of the base  60  is utilized to place the base  60  of the tile leveling device  14  under the tile TL 1  using motion N to gently pry the tile TL 1  upward while the base slides under the tile TL 1  with minimum displacement of mortar M. As best seen in  FIG.  21 B , following the positioning of the tile leveling device  14  with the tile TL 1 , tile TL 2  is placed with motion P onto the parallel strip members  78 . Once the tile leveling device  14  and tiles are positioned following the positioning best seen in  FIG.  21 C , the tile leveling device  14  and the wedge device  16  are selectively interconnected, as previously discussed, in  FIGS.  16 A through  16 C  and  FIGS.  17 A through  17 C . As best seen in  FIG.  21 D  through  FIG.  21 F , as the inclined plane  112  is continually pushed by a hand H, as shown by a motion O, through the tile leveling device  14  under the guide surface  34 , due to the increasing thickness of inclined plane  112  proximate the attachment end  104 , the action causes the lower surfaces of each of the tiles TL 1 , TL 2  to be compressed downward pressing the base  60  beneath the tiles  70 ,  72  toward the subsurface S, on which is located mortar M for bonding the tiles TL 1 , TL 2  to the subsurface S. As a result, the tiles TL 1 , TL 2  are aligned and leveled. The spacing between the tiles is controlled by the thickness of the upright body  18  and, in one embodiment, the presence of the spacers  46 ,  48 . Once the tiles TL 1 , TL 2  are set, the wedge device  12  may be removed and the upright body  14  is broken off by applying force to the side of the wedge device  16  such that the upright body  14  is severed at the frangible breakaway section  94 . In the illustrated implementation, the frangible breakaway section  94  is positioned such that it is located between the upper and lower surfaces of the tiles TL 1 , TL 2 . That is, the frangible breakaway section  94  is located at a height within the thickness of the installed tiles. In this position, the frangible breakaway section  94  is 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, which may form a channel break off area. 
     Referring now to  FIG.  22    and  FIG.  23   , it should be appreciated that variations in the tile leveling system  10  are within the teachings presented herein. By way of example, with reference to  FIG.  22   , and not by way of limitation, a tile leveling device  150  may include an upright body  152  having a head  154  coupled at one end and a base  156  coupled at the other end. As shown, in one embodiment, the upright body  152  includes spacers  158 ,  160 . Also, the head  154  includes a handle  162 . By way of further example, with reference to  FIG.  23   , a tile leveling device  180  may include an upright body  182  having a head  184  coupled at one end and a base  186  to the other end. As shown, the upright body  182  has enhanced thickness  188 , which provides spacer functionality by incorporating a spacer thickness therewith. Additionally, the head  184  includes a handle  190 . 
     As previously discussed, mechanical tile leveling systems have become increasingly popular. The tile leveling system  10  presented herein provides speed of operation through a simple system. Additionally, the present tile leveling system  10  decreases waste by providing a less wasteful, more compact solution. It is normal for thousands of clips to be used during a single tile installation job and as the tile leveling device  14  is intentionally divided in half at the base-to-body coupling  92 , waste is created, including the upright body  18  and the head  32 , for example. Compared to other tile leveling systems, the upright body  18  and the head  32  represent a reduction in the amount of waste as the upright  18  and the head  32  require approximately 75% less plastic than other mechanical tile leveling systems  10 . Importantly, however, the reduced plastic does not compromise strength due to the design of the tile leveling device  14 , including the upright body  18  interposed between the head  32  and the flared portion  54  that provide a wide bottom portion, strong pole portion, and wide top portion. 
     The order of execution or performance of the methods and techniques illustrated and described herein is not essential, unless otherwise specified. That is, elements of the methods and techniques may be performed in any order, unless otherwise specified, and that the methods may include more or less elements than those disclosed herein. For example, it is contemplated that executing or performing a particular element before, contemporaneously with, or after another element are all possible sequences of execution. 
     While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.