Tile Leveling Device Tension Gap System
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Solution Overview
Problem
Existing methods for laying ceramic tiles often fail to ensure proper leveling, leading to uneven surfaces and suboptimal mortar setting.
Innovation Solution
A tile leveling device comprising a tower, base, and leveling ridges with a tension gap system, along with a tensioner, that positions tiles in a level position and allows for mortar passage between the tiles and base, ensuring even spacing and improved mortar setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tile laying methods are used, then the process is simple, but the tiles cannot be properly leveled resulting in uneven surfaces
Solution Approach 1:
The leveling device is divided into distinct functional segments: the base that interfaces with the tile, the tower structure that provides height adjustment, and the leveling ridges that ensure proper positioning. This segmentation allows each component to be optimized independently while maintaining overall simplicity.
Solution Approach 2:
The tension gap system acts as an intermediary mechanism between the tile and the underlying surface, allowing for controlled mortar flow while maintaining precise leveling. The gap structure mediates between the need for structural support and the need for even mortar distribution.
2Reliability
If tiles are laid without a leveling device, then the laying process is faster, but the mortar setting is suboptimal leading to unstable installation
Solution Approach 1:
The leveling device is positioned and adjusted before the final tile setting occurs. The tower and base structure are pre-configured to establish the correct height and spacing, ensuring that when mortar is applied, it flows evenly from the start rather than requiring correction during the process.
Solution Approach 2:
The tension gap system automatically regulates mortar flow through its geometric design. As mortar is applied, the gap structure naturally channels and distributes it evenly without requiring additional intervention or complex control mechanisms, maintaining both speed and quality.
3Manufacturing precision
If a tension gap system is implemented, then mortar can flow freely improving setting, but the device structure becomes more complex
Solution Approach 1:
The complexity of the tension gap system is localized only to the specific areas where mortar flow control is needed - primarily at the interface between the base and the tile, and within the tower structure. The rest of the device maintains simple, straightforward geometry that is easy to manufacture and assemble.
Data Source
AI summary
For leveling tile, a tile leveling device (100) includes a tower (105), a base (120), and leveling ridges (130). The tower (105) includes a cross piece (110) and at least one strut that extends (115) in a distal direction (150) along a first axis (145) from the cross piece (110). Each strut (115) has a first traverse width (170). The base (120) is connected to the at least one strut (115) at a base intersection (140) and extends transversely from the at least one strut (115). The cross piece (110), the at least one strut (115), and the base (120) form a tension gap (125). The leveling ridges (130) are disposed on a proximal surface (121) of the base (120). Each leveling ridge (130) comprises a distal ridge side (131) connected to the base and a proximal ridge surface (132).