Patent Description:
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 the tiles are being placed on a substrate's surface. Proper alignment and leveling of each tile is important for a number of reasons. One reason is that if one tile is improperly placed, the error will continue in adjacent tiles such that the installation will be unacceptable and the tiles will have to be replaced and/or ground and polished until the tiles are level or flat. In addition to aesthetic reasons for properly laying tile, a level surface is essential in tile floors so that people do not trip on unevenly laid tiles. Replacing or otherwise correcting errors in tile installation takes time that adds to the total cost of the installation.

Laying and leveling tile can be difficult because many substrates are uneven, such as the ground substrate when laying tile for an outdoor patio. In this case, it can be difficult to raise the low areas of the substrate with mortar or other objects so that all the tiles are level. Further, tiles can shift and sink into mortar as the mortar dries. It has traditionally been necessary to continually monitor newly laid tiles as the mortar dries to ensure that the tiles remain level. Tile installers have used a variety of devices and methods to maintain quality tile installation while completing the installation process as fast as possible. One basic method uses markings on the substrate surface. Marking the installation surface requires the mortar to be carefully applied such that the marks remain visible. Although this technique aids in the alignment of the tiles, it does not keep the tiles level as they are laid in the mortar. Further, the use of this marking technique increases the amount of time required for the installation which results in increased cost.

Another device used for laying and leveling tile is a frame designed to space tiles at an appropriate distance. This type of frame is typically a fixed grid which is designed for a specific tile size. The disadvantage of this type of device is that it is a fixed size which requires a professional installer to carry multiple frames in order to be capable of installing various tile sizes. A further disadvantage of this type of frame is that it is only capable of installing one type of tile at a time.

Another device used to lay and align adjacent tiles leveling device such as the one shown and described in <CIT> (Torrents I Comas) wherein a cap slides downward along a shaft to secure the tile between the cap and a bottom plate. One drawback with this device is that a tightening tool is necessary to tighten the cap against the tile. The use of a tightening tool can increase the time it takes to complete the installation because the shaft of each leveling device must be threaded through an opening in the tightening tool in order for the tightening tool to tighten the cap against the tile.

<CIT> discloses a tile aligning and lippage tunning system, having a base member, a handle, and a locking assembly, which is suitable for aligning tiles. An assembly according to the preamble of claim <NUM> is known from said document.

<CIT> discloses a tile alignment and leveling device for aligning and leveling tiles as they are secured to a substrate, in which there is a base member having pivotable members attached thereto.

Therefore, there is a need for an efficient and inexpensive tile leveling and alignment device which overcomes the drawbacks in the prior art and does not require threading a tightening tool onto an elongated shaft.

One aspect of the invention relates to a tile alignment assembly for laying and leveling adjacent tiles as claimed in claim <NUM>. Optional features are laid out in claims <NUM> to <NUM>. A further aspect of the invention relates to a method for laying and leveling first and second tiles using the tile alignment assembly is outlined in claim <NUM> below. An optional feature of the method is laid out in claim <NUM>.

Not in accordance with the present invention, there is provided an alignment assembly comprises a base member having a bottom plate and an intermediate member extending upwardly from the bottom plate. The intermediate member has a first side and a second side, wherein the first and second sides of the intermediate member have an engagement member extending outwardly therefrom. The assembly further comprises a cam tool having a handle combined with a first cam member and a second cam member, wherein each cam member has a tile engaging surface around its outer periphery, and wherein each tile engaging surface has a first portion that is a first distance from an opening that defines an axis of rotation and a second portion that is a second distance from the axis of rotation. The engagement member extending from the base member is adapted to receive the opening in the cam member thereby allowing the cam tool to rotate relative the base member so that the first cam member is on one side of the intermediate member and the second cam member is on a second side of the intermediate member. Rotation of the cam tool around the axis of rotation causes the distance between the tile engaging surface and the bottom plate to change. The cam member's tile engaging surface may be a smooth curve or it may by the shape of a polygon comprising a plurality of separate generally straight sides separated by vertices. One or more tiles is adapted to be placed between the tile engaging surface of the cam member and the bottom plate of the base member and compressed as the cam tool is rotated to a desired position.

Not in accordance with the present invention, there is provided an assembly generally includes a cam tool adapted to engage and rotate relative to a base member. The cam tool has a handle combined with a cam member, the cam member has a plurality of generally flat tile engaging surfaces around its outer periphery angled relative to each other, wherein each tile engaging surface is a different distance from an opening that defines an axis of rotation. In one embodiment the plurality of flat tile engaging surface form a polygon or a portion of a polygon (i.e., a polygon which is not completed or closed). The opening includes an engagement surface. The base member has a bottom plate and an intermediate member extending upwardly from the bottom plate. The intermediate member includes at least one engagement member, which is a shaft extending outward. The engagement surface of the cam member's opening is adapted to engage and rotate around the engagement member. One or more tiles is adapted to be placed between the tile engaging surface of the cam member and the bottom plate of the base member. Since the rotation axis is off-center, each tile engaging surface is a different distance from the bottom plate when facing downward thereby the tile(s) to be compressed between the cam member and the bottom plate.

The cam member of the cam tool comprises a rounded shape such as a circle, semi-circular, oval, or any other fraction of a circle or oval. The axis of rotation may be off-center with respect to the outer tile engaging surface of the cam member so that the rotation axis is a different distance from each point on the tile engaging surface. An opening in the cam member may be adapted to receive the engagement member extending from the base member such that rotating the cam tool around the engagement member of the bottom plate causes the tile engaging surface to get closer to the bottom plate. Since the axis of rotation is off-center, the tile engaging surface gets closer to the bottom plate as the cam tool is rotated thereby allowing the tile(s) to be compressed between the cam member and the bottom plate. The locking assembly allows the cam tool to be rotated in a first direction relative to the base member but not in a second (opposite) direction.

Not in accordance with the present invention, there is provided a method of using an assembly for laying and leveling adjacent tiles. The method includes placing an assembly like the ones described above on a substrate surface. In use, one or more tiles are placed on the bottom plate on either side of the intermediate member and the cam tool is pivotally combined with the base member. The cam tool is rotated around the axis of rotation until the tile engaging surface on each of the cam members engages and compresses the tiles to secure the adjacent tiles at the same height as the setting bed cures and hardens. After the setting bed has cured and hardened, the intermediate member is separated from the bottom plate at the separate point. The cam tool may be reused in subsequent tile leveling operations.

The present invention is an assembly for laying, aligning, and leveling tiles. The assembly can be used to align and level tiles 26a, 26b that are being secured to any suitable substrate, including floors, walls, and countertops. It should be noted that words used in this specification such as upper, lower, top, and bottom, are relative to the device as it is shown in <FIG>.

<FIG> shows the general components of a first embodiment of the assembly. The assembly generally includes a cam tool <NUM> adapted to engage a portion of a base member <NUM> and rotate relative to the base member <NUM> around an axis of rotation. The cam tool <NUM> is shaped to convert rotational motion into linear (downward) motion/force as described herein. <FIG> and <FIG> show the cam tool <NUM> without the base member <NUM>. The cam tool <NUM> has a handle <NUM> combined with a cam member <NUM>. The cam member <NUM> includes a tile engaging surface <NUM> around its outer periphery, wherein the tile engaging surface <NUM> includes multiple portions which are a different predetermined distance from the axis of rotation. In one embodiment not in accordance with the present invention the cam member <NUM> comprises a tile engaging surface <NUM> having a plurality of generally flat portions which are separated by vertices or corners. In one embodiment not in accordance with the present invention the plurality of flat portions of the tile engaging surface <NUM> form a polygon or a portion of a polygon (i.e., a polygon which is not completed or closed as shown in <FIG>). The portions of the tile engaging surface <NUM> do not need to be the same length or be separated by the same angle. In another embodiment the tile engaging surface <NUM> is a continuous curve as described below with respect to <FIG>.

The base member <NUM> is shown in <FIG> and <FIG> without the cam tool <NUM>. The base member <NUM> has a bottom plate <NUM> and an intermediate member <NUM> extending upwardly from the bottom plate <NUM>. The intermediate member <NUM> includes at least one engagement member <NUM>, which is a shaft extending outwardly therefrom. There is a predetermined distance between the engagement member <NUM> and the bottom plate <NUM>. The cam tool <NUM> may be combined with the base member <NUM> by any suitable means. In the embodiment shown, the cam tool <NUM> has an opening such as a notch which includes an engagement surface <NUM>. The opening/notch is adapted to receive the engagement member <NUM> extending from the base member <NUM> to allow the components to rotate relative to each other around an axis of rotation. The axis of rotation is off-center with respect to tile engaging surface <NUM> of the cam member <NUM> so that the axis of rotation is a different distance from various portions of the tile engaging surface <NUM>. As explained in more detail below, the cam tool <NUM> rotates relative to the base member <NUM> causing each successive portion of the tile engaging surface <NUM> to face downward toward the bottom plate <NUM> as the cam tool <NUM> is rotated. Since the axis of rotation is off-center, each successive portion of the tile engaging surface <NUM> is a different distance from the bottom plate <NUM> when it is rotated to face downward toward the bottom plate <NUM>. In one embodiment, starting at one end of the cam member <NUM>, each successive portion of the tile engaging surface <NUM> is farther from the axis of rotation (and closer to the bottom plate <NUM>) as the cam tool <NUM> is rotated to reduce the space between the tile engaging surface <NUM> and the bottom plate <NUM> and increase the force applied to the tile(s) positioned between the components <NUM>, <NUM>. The compression of the engaging surface <NUM> against the tiles <NUM> helps ensure the top surface of the tiles <NUM> are held at the same elevation as the setting bed <NUM> dries to help reduce lippage between the tiles <NUM>.

As shown best in <FIG> and <FIG>, one embodiment of the cam tool <NUM> has a first cam member <NUM> separated from a second cam member <NUM> by a space or opening <NUM>. Each cam member <NUM>,<NUM> has a tile engaging surface <NUM>,<NUM>. The tile engaging surface <NUM> on the first cam member <NUM> is adapted to engage a first tile 26a on a first side of the base member <NUM> and the tile engaging surface <NUM> on the second cam member <NUM> is adapted to engage a second tile 26b on a second side of the base member <NUM>. The opening <NUM> between the first cam member <NUM> and the second cam member <NUM> is at least large enough to allow the base member <NUM> to pass through as the cam tool <NUM> is rotated around the base member <NUM>. In one embodiment the tile engaging surfaces <NUM>,<NUM> are mirror images of each other so that they both engage their respective tiles 26a, 26b at the same time with the same amount of force. This helps to ensure that both tiles 26a, 26b are level with respect to each other as the mortar/setting bed <NUM> cures and hardens.

In use, the cam member <NUM> is rotated to a position where it engages the top surface of the tile 26a, 26b and presses the tile 26a, 26b downward against the bottom plate <NUM>. If the tile 26a, 26b was removed, the distance between the tile engaging surface <NUM>,<NUM> and the bottom plate <NUM> would be less than the thickness of the tile 26a, 26b. With the tile 26a, 26b in place, the cam member <NUM> and base member <NUM> have some elasticity allowing them to stretch from a first position to a second position to accommodate the thickness of the tile 26a, 26b positioned between these components <NUM>,<NUM>. The components <NUM>, <NUM> are biased in their first position thereby creating a compressive force on the tile 26a, 26b as the components <NUM>,<NUM> try to return to their first position. The compressive force helps keep the adjacent tiles 26a, 26b level relative to each other. The compressive force also helps keep the cam member <NUM> from rotating once it has been set against the tiles 26a, 26b. The force needed to rotate the cam member <NUM> one way or the other is greater than the force applied along the surface of the tile engaging surface <NUM>, <NUM> because the distance from the rotation axis to the vertices or corners is greater than the distance from the rotation axis to the respective tile engaging surface <NUM>, <NUM>.

In one embodiment the cam tool <NUM> includes reinforcement members <NUM> such as spokes which separate the tile engaging surface <NUM> from the engagement surface <NUM>. As shown in <FIG>, a first reinforcement member 15a is shorter than a second reinforcement member 15b so that the tile engaging surface <NUM> adjacent to second reinforcement member 15b extends out farther from the rotation axis than the tile engaging surface <NUM> adjacent to the first reinforcement member 15a. This allows the portion of the tile engaging surface <NUM> adjacent to the second reinforcement member 15b to be closer to the bottom plate <NUM> than the portion of the tile engaging surface <NUM> adjacent to the first reinforcement member 15a when the respective portions of surface <NUM> are rotated to face the bottom plate <NUM>.

One embodiment of the cam tool <NUM> includes visual markings which correspond to each tile engaging surface <NUM> to inform the user which surface <NUM> is intended for use with which tile thickness. In use, the thinner the tile 26a, the farther the tile engaging surface <NUM> must be from the axis of rotation to apply the appropriate amount of compressive force to the tile 26a. Any suitable marking may be used, including English units (inches) and Metric units (millimeters). The embodiment shown uses fractions of an inch. In <FIG>, for example, the tile thickness D1 is about <NUM>/<NUM> of an inch. The cam tool <NUM> is secured to the base member <NUM> then rotated (clockwise in this embodiment) until the <NUM>/<NUM> inch marking is facing downward and engaging the top surface of the tile <NUM>. The <NUM>/<NUM> inch marking on the cam tool <NUM> indicates that the distance between the tile engaging surface <NUM> engaging the tile <NUM> to the top surface of the bottom plate <NUM> is about <NUM>/<NUM> of an inch (i.e., the height of the tile <NUM>). Similarly, <FIG> shows a different tile <NUM> having a tile thickness D2 of about <NUM>/<NUM> of an inch. The distance between the tile engaging surface <NUM> facing downward to the top surface of the bottom plate <NUM> is about <NUM>/<NUM> of an inch. In some embodiments the actual distance between the downward facing engaging surface <NUM> and the bottom plate <NUM> is less than the distance shown by the visual marking to help ensure the engaging surface firmly engages the tile <NUM> and/or applies force to compress the tile <NUM> against the bottom plate <NUM>.

<NUM>-<NUM> show an alternate embodiment wherein the engagement surfaces 18a, 19a do not include a plurality of flat portions. Instead, the engagement surfaces 18a, 19a are curved such as a portion of a circle or oval as shown best in <FIG>. In this embodiment, the engagement surfaces 18a, 19a are secured against the tiles 26a, 26b by rotating the cam tool <NUM> relative to the base portion <NUM> as described in the previous embodiment. In this embodiment, however, a locking assembly such as a ratchet or locking pawl assembly secures the cam tool <NUM> relative to the base portion <NUM> after the cam tool <NUM> has been rotated to a desired position applying a desired amount of force against the tiles 26a, 26b. <FIG> shows the finger or pawl members <NUM> extending inward from each tile engaging surface 18a, 19a of the cam tool <NUM>. <FIG> shows the gear or teeth members <NUM> combined with the base member <NUM> around the axis of rotation and adapted to interfere with the pawl members <NUM> as the cam tool <NUM> is rotated. One of the pawl members <NUM> and the teeth members <NUM> are asymmetrical thereby allowing the components <NUM>, <NUM> to move past each other in a first direction but not in a second (opposite) direction. It should be noted that in some embodiments these components are reversed with the pawl members <NUM> on the base member <NUM> and the teeth <NUM> on the cam tool <NUM>. The locking assembly allows the cam tool <NUM> to rotate relative to the base member <NUM> in a first direction but not in a second (opposite) direction. <FIG> and <FIG> are other views of the components showing the locking assembly.

As shown best in <FIG>, the bottom plate <NUM> preferably comprises one or more openings <NUM>. The openings <NUM> allow the setting bed material <NUM> to seep through the bottom plate <NUM> to bond with the portion of the tile 26a, 26b directly above the bottom plate <NUM>, which otherwise may not contact much of the setting bed material <NUM>. Further, the seepage helps to ensure that the tiles 26a, 26b remain level as forces are applied to the bottom plate <NUM>, setting bed material <NUM>, and/or tiles 26a, 26b as the cam tool <NUM> is rotated to its tightened position. If the setting bed material <NUM> was not allowed to seep through the bottom plate <NUM>, the setting bed material <NUM> could raise the bottom plate <NUM> as it dried which would consequently affect the level of the tiles 26a, 26b.

After the setting bed <NUM> dries and the tiles 26a, 26b are secured to the substrate <NUM>, the user removes the portion of the device that is visible above the laid tiles 26a, 26b, i.e. the intermediate member <NUM>. In one embodiment, the intermediate member <NUM> comprises a separation point <NUM> near the connection of the intermediate member <NUM> and the bottom plate <NUM> as seen in <FIG>. The separation point <NUM> is structurally weaker than the remainder of the intermediate member <NUM> so that the user can apply force to the portion of the intermediate member <NUM> that extends above the tiles 26a, 26b and cause the intermediate member <NUM> to break at its separation point <NUM>. The separation point <NUM> may comprise a single opening which allows the separation point <NUM> to be structurally weaker and separate when the proper force is applied by the user. Alternatively, the separation point <NUM> comprises a plurality of micro holes or perforations which allow the separation point <NUM> to be structurally weaker and separate when the proper force is applied by the user. In one embodiment, the curing process of the setting bed <NUM> pulls moisture out of the intermediate member <NUM> making it more brittle. This makes it easier for the user to break the intermediate member <NUM> at the separation point <NUM>. Once separated at the separation point <NUM>, the bottom plate <NUM> remains below the tiles 26a, 26b and is therefore not reusable. The cam tool <NUM>, however, can be removed from the engagement member <NUM> and reused in subsequent tile laying operations.

<FIG>, <FIG>, and <FIG> show an embodiment wherein at least a portion of the bottom plate <NUM> is comprised of a material that has a flexible or spring-like quality, such as a plastic composite. The outer edges or corners ("wings") of the bottom plate <NUM> are flexible and can move between a compressed position and an extended position. The outer edges of the bottom plate <NUM> are biased in their extended position. As the cam tool <NUM> is tightened against the top surface of the tiles <NUM>, the flexible portions of the bottom plate <NUM> are compressed downward toward the substrate <NUM> and exert an upward force against the bottom of the tile <NUM> as they try to return to their extended position. The outer edges of the bottom plate <NUM> may be tapered so that they are thinner at the outer tip to allow the device to be easily inserted under tiles 26a, 26b.

The embodiment comprising the flexible portions of the bottom plate <NUM> is useful in situations where two adjacent tiles 26a, 26b have different thicknesses. The edges of the bottom plate <NUM> can be compressed under the weight of the thicker (heavier) tile 26a, while the flexible or spring-like quality of the bottom plate <NUM> can remain in its extended position under the thinner (lighter) tile 26b thereby holding the two adjacent tiles 26a, 26b at the same elevation. In the manner, the tile alignment and leveling device is self-adjusting after it has been placed under the tiles 26a, 26b. When the device is used at the intersection of four tiles, each of the outer corners of the bottom plate <NUM> can be positioned under each of the four tiles to independently hold each tile at the same elevation. Although this embodiment is shown in <FIG> as having four flexible wing portions, the flexible edges can be any other suitable shape with any suitable number of flexible wings.

<FIG> and <FIG> show the assembly being used to level and align adjacent tiles 26a, 26b. It should be appreciated that any number of assemblies may be used to align dozens or hundreds of tiles during the installation of a single tile surface. In use, a typical first step in laying tile 26a, 26b is to apply a setting bed <NUM> such as mortar or cement to the substrate surface <NUM>. After the setting bed <NUM> is applied, the tiles 26a, 26b can be placed on the substrate surface <NUM> in the setting bed <NUM> then the tiles 26a, 26b are placed on the bottom plate <NUM>. In use, the bottom plate <NUM> is positioned in the setting bed <NUM> beneath the tiles 26a, 26b so that the intermediate member <NUM> extends upward between adjacent tiles 26a, 26b as shown in <FIG>. The cam tool <NUM> is combined with the engagement member <NUM> then rotated so that the distance between the axis of rotation and the engagement surface <NUM> increases (clockwise in <FIG> & <FIG>). The rotation continues until the engagement surface <NUM> presses firmly on the top surface of the tile 26a, 26b. The tiles 26a, 26b are secured between the bottom plate <NUM> and the tile engaging surface <NUM> so that adjacent tiles 26a, 26b are level regardless of whether the underlying substrate material <NUM> is level. The bottom plate <NUM> does not need to rest on the substrate in order for the tiles 26a, 26b to be level. The bottom plate <NUM> may even be suspended above the substrate <NUM> as long as at least a portion of the tile 26a, 26b is contacting the setting bed <NUM> and as long as the tiles 26a, 26b are level relative to each other. The bottom plate <NUM> and engagement surface <NUM> hold the tiles 26a, 26b at the same height so that corners and/or edges of the adjacent tiles 26a, 26b remain aligned and level as the setting bed <NUM> cures and hardens.

After the setting bed <NUM> dries, and the tiles 26a, 26b are secured to the substrate <NUM>, the user removes the portion of the device that is visible above the laid tiles 26a, 26b. As seen in <FIG>, the base member <NUM> comprises a separation point <NUM> near the connection of the base member <NUM> and the bottom plate <NUM>. In the preferred embodiment, the separation point <NUM> is structurally weaker than the remainder of the base member <NUM> so that the user can twist the base member <NUM> above the tiles 26a, 26b and cause the base member <NUM> to break at the separation point <NUM>. Although the separation point <NUM> is capable of breaking when twisted, it is strong enough so that when force is applied longitudinally along the length of the base member <NUM>, the base member <NUM> does not break. Once separated at the separation point <NUM>, the bottom plate <NUM> remains below the tiles 26a, 26b and is therefore not reusable. The cam tool <NUM>, however, can be removed from the base member <NUM> and reused in subsequent tile laying. As discussed above, the base member <NUM> is preferably made of a semi-rigid plastic, which helps the base member <NUM> to more easily be broken at its separation point <NUM>.

Claim 1:
A tile alignment assembly comprising:
a base member (<NUM>) having a bottom plate (<NUM>) and an intermediate member (<NUM>) extending upwardly from the bottom plate (<NUM>), wherein the intermediate member (<NUM>) has a first side and a second side;
a cam tool (<NUM>) pivotally combined with the base member (<NUM>) to rotate around an axis of rotation, said cam tool (<NUM>) having a handle (<NUM>) combined with a cam member (<NUM>), wherein the cam member (<NUM>) has a rounded tile engaging surface (18a) around its outer periphery with a plurality of successive points, wherein each successive point is farther from the axis of rotation so the distance between the tile engaging surface (18a) and the bottom plate (<NUM>) decreases as the cam tool (<NUM>) is rotated in a first direction;
characterized in that said intermediate member (<NUM>) has a shaft (<NUM>) extending outwardly from the first side, and that said cam tool (<NUM>) has an off-center notch (<NUM>) adapted to receive the shaft (<NUM>) to allow the cam tool (<NUM>) to be rotated around the shaft (<NUM>), and
a locking pawl assembly combined with the base member (<NUM>) and the cam tool (<NUM>), said locking pawl assembly having pawl members (<NUM>) configured to interfere with teeth members (<NUM>) allowing the cam tool (<NUM>) to rotate in the first direction relative to the base member (<NUM>) but not in a second opposite direction relative to the base member (<NUM>).