Tile Leveling Device with Adjustable Locking Assembly
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Solution Overview
Problem
Existing tile installation methods face challenges in aligning and leveling tiles due to uneven substrates, tile shifting during mortar drying, and the need for continuous monitoring, leading to increased costs and potential tripping hazards from uneven surfaces.
Innovation Solution
A tile leveling and alignment device comprising a locking assembly and a bottom plate with a shaft that allows for adjustable tile alignment and locking after tiles are laid, applying a constant force to prevent shifting during mortar curing, and can be reused in subsequent installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional marking methods are used to guide tile alignment, then alignment can be maintained, but installation time increases and cost increases
Solution Approach 1:
The tile leveling device automatically maintains alignment and leveling as tiles are installed, eliminating the need for continuous manual monitoring and marking. The device self-adjusts to compensate for substrate irregularities, allowing installers to work faster without sacrificing precision.
Solution Approach 2:
The tile leveling device acts as an intermediary tool between the installer and the tiles, providing mechanical guidance and force to maintain proper alignment and leveling. This mediator device eliminates the need for direct manual intervention with markings and continuous adjustment.
2Manufacturing precision
If fixed size frames are used for tile installation, then specific tile sizes can be installed, but multiple frames are required for different tile sizes increasing complexity
Solution Approach 1:
The tile leveling device is designed to work with multiple tile sizes and installation configurations through a single universal design. The adjustable components allow the same device to accommodate various tile dimensions and substrate conditions, eliminating the need for multiple specialized frames.
Solution Approach 2:
The device incorporates adjustable and movable components that can adapt to different tile sizes and installation scenarios. Rather than being a fixed frame, the device dynamically adjusts its geometry and configuration to match the specific installation requirements.
3Manufacturing precision
If height adjustment means is located under the tile, then alignment can be maintained, but adjustment cannot be made after tile is laid
Solution Approach 1:
Instead of placing the adjustment mechanism underneath the tile where it is inaccessible, the invention positions the height adjustment means on the upper portion of the device where it is easily accessible. This allows installers to make corrections after the tile is laid by simply adjusting the device from above.
4Manufacturing precision
If mortar is applied to raise low substrate areas, then leveling can be achieved, but tile shifting during drying occurs
Solution Approach 1:
The tile leveling device is positioned and adjusted before the mortar fully cures, providing immediate mechanical stabilization to prevent tile shifting during the critical drying period. The device's locking mechanism secures the tile in the correct position while the mortar sets.
Solution Approach 2:
The device provides continuous mechanical feedback and correction during the mortar drying process, allowing the installer to make real-time adjustments to compensate for substrate irregularities and prevent tile shifting before the final set occurs.
Data Source
AI summary
A device for aligning and leveling tiles as they are laid in floors, walls, countertops, or the like. The device has a locking assembly and a bottom plate combined with a shaft that extends from the bottom plate through the locking assembly so that the locking assembly is movable along the length of the shaft. In use, the device is placed between adjacent tiles so that the locking assembly and bottom plate hold adjacent tiles at a desired height as the setting bed dries. The locking assembly has flexible members adapted to exert a constant compressive force against the tiles during the tile leveling process.