Perforated Leveling Spacer for Tile Adhesive Flow
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Solution Overview
Problem
Existing leveling spacers for uneven tiles do not effectively allow adhesive to flow through for secure attachment and leveling, especially when tiles are of different widths or installed over uneven surfaces, leading to potential tripping hazards and aesthetically unappealing installations.
Innovation Solution
A perforated rectangular plastic spacer that allows adhesive to flow through perforations for secure attachment to uneven tiles, providing a solution for leveling and securing tiles of different dimensions, including mosaics, while maintaining structural integrity with a reinforced perimeter and adjustable height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid non-perforated spacer is used, then structural integrity is maintained, but adhesive cannot flow through for secure attachment
Solution Approach 1:
The spacer incorporates perforations throughout its body, transforming it from a solid non-porous structure to a porous one. This allows adhesive to flow through the spacer and bond the tile to the substrate, while the perforated structure maintains sufficient structural integrity to support the tile during installation and curing.
2Ease of manufacture
If a simple spacer design is used, then manufacturing cost is reduced, but leveling capability for uneven surfaces and different width tiles is insufficient
Solution Approach 1:
The spacer features an asymmetric design with a first width and a second width that differ from each other. This asymmetric geometry enables the spacer to accommodate tiles of different widths and to level uneven surfaces effectively, while still being manufacturable as a single molded piece.
Solution Approach 2:
The spacer utilizes vertical dimension with a predetermined height to provide leveling capability. By extending in the vertical dimension, the spacer can compensate for uneven surfaces and create a level bonding surface for tile installation, adding functional capability without significantly increasing manufacturing complexity.
3Reliability
If a perforated spacer is used, then adhesive flow through is enabled for secure attachment, but structural complexity increases
Solution Approach 1:
The spacer incorporates perforations throughout its body, transforming it from a solid non-porous structure to a porous one. This allows adhesive to flow through the spacer and bond the tile to the substrate, while the perforated structure maintains sufficient structural integrity to support the tile during installation and curing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures safe and aesthetically pleasing installations by leveling uneven surfaces, reducing tripping hazards and facilitating efficient installation of tiles and mosaics, while being cost-effective and easy to maintain.
Implementation Method 1
the perforations in the spacer allow for the cement or mastic product to flow into the spacer and cause it to adhere to the tile
Data Source
AI summary
A system for a leveling spacer including a spacer assembly, a tile assembly and a mosaic assembly is disclosed. The leveling spacer is used to level tiles on an uneven surface. The spacer includes cross members that define perforations therebetween. Adhesive of the tile assembly is placed on the uneven surface. The spacer is mounted onto the adhesive which seeps through the perforations. Tiles of the tile assembly are then secured onto the spacer with the adhesive that seeped through. The tiles are leveled on the spacer to a height that matches surrounding tiles. The spacer comes in various heights to allow leveling as needed.