Tile Leveler Wedge With Segmented Sawtooth Locking
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Solution Overview
Problem
Existing wedge levelers for tiles require additional tools, such as clamps, to insert the wedge, making the process difficult and risking damage to the device.
Innovation Solution
A wedge leveler design featuring a disposable element with a flexible tongue and sawtooth portion on the wedge's inclined face allows for easy insertion and locking without additional tools, using a cylindrical body for smooth movement and an arched element for comfortable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If knurling is added to the wedge ramp to enable locking with the protruding tongue, then the wedge can be locked in the chosen position, but it becomes difficult to push the wedge into the opening
Solution Approach 1:
The interaction surface between the wedge and disposable element is segmented into two distinct zones: a smooth insertion zone that allows easy penetration into the opening, and a knurled locking zone that engages with the protruding tongue to secure the wedge in position. This segmentation resolves the contradiction by providing different surface characteristics for different operational phases.
Solution Approach 2:
Instead of having knurling throughout the entire wedge surface which would prevent insertion, the knurling is inverted to appear only at the locking interface where it is needed. The insertion face remains smooth while the locking face contains the knurling pattern, allowing the wedge to be easily inserted then securely locked.
2Ease of operation
If a clamp is used to push the wedge into the opening, then the wedge can be inserted, but additional tools are required and there is a risk of damaging the wedge and/or disposable element
Solution Approach 1:
The wedge is designed with a geometry that enables self-insertion into the disposable element without requiring external clamping tools. The smooth insertion face and optimized angles allow the wedge to be pushed in manually, and the protruding tongue with knurled engagement provides self-locking functionality, eliminating the need for additional tools and reducing damage risk.
3Ease of operation
If the wedge is designed with a smooth surface for easy insertion, then insertion is simple, but the wedge cannot be locked in position
Solution Approach 1:
The wedge surface is segmented into distinct functional zones: a smooth insertion face that facilitates easy penetration into the disposable element, and a knurled locking face that engages with the protruding tongue to maintain position stability. This spatial segmentation allows both easy insertion and reliable locking to coexist.
Solution Approach 2:
Different local regions of the wedge are assigned different surface qualities: the insertion area has a smooth finish to minimize friction and allow easy entry, while the locking area features a knurled texture to maximize friction and engagement with the protruding tongue, ensuring stable positioning.
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
Enables simple and tool-free operation for making tile faces coplanar, reducing the risk of damage and facilitating easy retrieval of the wedge for reuse.
Implementation Method 1
a tongue protrudes downwards from the lamella and has a free end with a lower face on one side and is fixed to the lamella on the other side so as to be flexible and inclinable
Implementation Method 2
when the wedge tries to get out, the free end of the tongue abuts on one of the teeth, in particular on its perpendicular face, and prevents the wedge from leaving the opening
Implementation Method 3
a first cylindrical body may protrude from the lamella downwards in the opening, the main axis of the cylindrical body being parallel to the faces of the tiles P and a first smooth lateral portion may be formed on the inclined upper face and the first cylindrical body can slide on said smooth lateral portion
Data Source
Figure 1
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AI summary
The invention concerns a leveler (10) to make coplanar the faces of two adjacent tiles (P) without using pincers or other tools. The leveler (10) uses a disposable element (12) and a wedge (14) comprising a sawtooth formation thereon cooperating with a tongue on the disposable element, the wedge being adapted to be inserted in the disposable element so as to push down the tiles and make them coplanar.