One-Piece Tile Levelling Assembly for Faster Ceramic Installation
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Solution Overview
Problem
Existing tile-levelling systems for ceramic tiles are complex, costly, and time-consuming due to their multi-piece design, requiring separate moulds, tools for assembly, and inefficient reuse processes, limiting their applicability and increasing installation costs.
Innovation Solution
A one-piece ceramic-tile levelling system with a partially-threaded stem and torque hood attached via frangible connections, allowing single-hand operation and easy assembly, manufactured in a single mould, and featuring a flat region for consistent spacing and easy separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a multi-piece levelling system is used, then the levelling function can be achieved, but the device complexity increases and manufacturing cost rises
Solution Approach 1:
The patent combines multiple separate components (base, stem, and tightening component) into a single integrated levelling apparatus. The base includes an integrated stem with frangible connections and a tightening component, eliminating the need for separate assembly of multiple pieces. This merging reduces device complexity and manufacturing cost by requiring only a single mould for production.
2Productivity
If a multi-piece levelling system is used, then the levelling function can be achieved, but the installation time increases
Solution Approach 1:
The stem and tightening component are pre-integrated into the base structure during manufacturing, with frangible connections already in place. This preliminary integration eliminates the need for on-site assembly of multiple components, allowing the installer to simply place the single-piece apparatus between tiles and break the frangible connections to activate the levelling function, significantly reducing installation time.
3Ease of operation
If a multi-piece levelling system is used, then the levelling function can be achieved, but the operation becomes more difficult
Solution Approach 1:
By merging the base, stem, and tightening component into a single integrated apparatus, the patent reduces the number of components the operator must handle. The single-piece design with pre-integrated frangible connections simplifies the operation to placing one apparatus between tiles and breaking the connections, eliminating the complexity of assembling and coordinating multiple separate components.
4Ease of manufacture
If separate moulds are used for manufacturing, then different components can be produced, but the manufacturing cost increases
Solution Approach 1:
The patent integrates all levelling components into a single apparatus that can be manufactured in one mould. The base includes an integrated stem with frangible connections and a tightening component, all formed in a single injection moulding process. This eliminates the need for multiple separate moulds and the complex assembly process, reducing manufacturing cost and simplifying production while maintaining production flexibility.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3D
AI summary
This invention refers to a one-piece ceramic-tile levelling system comprised of a base from which a longitudinally partially-threaded stem rises perpendicular to the flat surface of the base. The device also consists of a torque hood composed of a partially-threaded cylindrical orifice, to the walls of which said stem is attached in an arrangement concentric to said orifice by means of frangible connections. The stem thread and the torque hood thread are complementary to one another so that when the frangible connections are broken, the torque hood is screwed onto the stem in such a way that a face of the torque hood parallel to the flat surface of the base closes in on the same, levelling the two adjacent tiles as it does so.