Tile Leveller Stem with Frangible Breakaway
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Solution Overview
Problem
Tiling processes face challenges such as sagging tiles due to glue imperfections, air gaps, heat expansion, and misalignment, which are difficult to address with existing mechanical devices, particularly in adhering to Australian Standards for tile spacing and levelling.
Innovation Solution
A tile spacer and levelling system comprising a base and stem with a cross-shaped profile, a frangible portion, and a ratchet mechanism, along with a levelling hand tool for precise spacing and levelling of tiles, allowing for easy removal of the spacer after adhesive curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional plastic crosses are used as spacers, then tile spacing can be maintained, but the crosses are difficult to remove and may be left in place breaching Australian Standards
Solution Approach 1:
The tile leveller is divided into two separate components: a reusable leveller body and a disposable stem with spacer. The stem is attached to the leveller, used for spacing and levelling, then removed and discarded after use. This segmentation allows the spacer function to be temporary and disposable, solving the removal difficulty while ensuring standards compliance.
Solution Approach 2:
The stem with integrated spacer is designed as a disposable component that is attached to the leveller for use, then removed and discarded. This eliminates the need to repeatedly remove and reuse spacers, ensuring Australian Standards compliance while maintaining ease of operation. The reusable leveller body combines with new disposable stems for each tiling task.
2Measurement precision
If manual visual alignment is attempted, then no additional devices are needed, but alignment precision is insufficient and results are unsightly
Solution Approach 1:
The stem is pre-attached to the leveller body before use, with the spacer portion extending outward to establish precise spacing and alignment references. This preliminary configuration eliminates the need for separate alignment tools and provides built-in precision guidance during tile placement.
Solution Approach 2:
The tile leveller combines multiple functions into a single device: spacing (via the stem extension), levelling (via the leveller body), and alignment (via the integrated cross profile). This multi-functionality provides precise alignment without requiring multiple separate devices, balancing measurement precision with acceptable device complexity.
3Manufacturing precision
If the leveller is restricted to only move downward along the stem, then tile levelling control is improved, but the mechanism becomes more complex
Solution Approach 1:
The ratchet mechanism replaces complex multi-component mechanical systems with a simpler one-way engagement system. The ratchet teeth on the stem engage with corresponding features on the leveller body, allowing downward movement while preventing upward movement. This simplified mechanical substitution achieves precise levelling control with minimal complexity.
4Ease of operation
If the stem includes a frangible portion for easy removal, then spacer removal becomes simple, but the stem may break during normal use
Solution Approach 1:
The stem is designed with non-uniform properties: the majority of the stem maintains full structural strength for normal use, while a specific localized portion (the frangible portion) is weakened through reduced wall thickness or material changes. This local quality differentiation allows easy removal at the frangible point while maintaining overall stem strength during levelling operations.
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 accurate and efficient spacing and levelling of tiles, maintaining aesthetic alignment and compliance with standards by allowing for precise control over tile alignment and levelling, with the ability to visually inspect the tile joint during and after the levelling process.
Implementation Method 1
a ratchet mechanism such that the tile leveller is restricted to only move downward along the stem toward the base
Implementation Method 2
at least one of the projections and teeth are resilient and orientated to allow one way movement of the stem with respect to the stem engaging portion
Implementation Method 3
a frangible portion located between the base and the tile alignment portion
Data Source
Figure 1
Figure 2~3D
Figure 4A~5
AI summary
A tile leveller and spacer system that allows rapid and reliable spacing and levelling of tools is described. The tile spacer comprises a base for locating the spacer under the tiles, and a stem that includes an alignment cross which is used to correctly space the tiles. The stem tile spacer is placed over the stem and engages with teeth on the stem. The tile leveller is pushed down over the stem to level the tiles between the base and the bottom of the tile leveller. The stem further comprises a frangible portion located between the base and the tile alignment portion, and when the stem is pulled with sufficient force, the frangible portion breaks to allow removal of the stem. A hand tool may be used to assist in this process. The hand tool can have an adjustable stop which can be set to a first setting to level the tiles, and a second setting to cause the frangible portion to break, allowing removal of the stem and leveller.