Wedge Leveling System with Frangible Base Connections
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Solution Overview
Problem
Existing tile and surface protective covering leveling devices are expensive, often require additional spacers or tools, and do not consistently provide acceptable alignment results due to frangible connections being above the base or in incorrect positions.
Innovation Solution
A wedge leveling system with a tab featuring a base and vertical member, where the vertical member is held between tiles and a wedge is inserted to align them, with frangible connections below the base for easy removal after setting, minimizing the need for separate spacers and ensuring correct alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If frangible connections are positioned in or above the base at different positions, then the levelling device can be designed with varied connection points, but the results are inconsistent and additional spacers or tools are required
Solution Approach 1:
The patent positions the frangible connection at a specific local region - the rear end of the vertical member below the base. This localized positioning ensures that the connection always breaks at the same predetermined location, providing consistent alignment results without requiring additional spacers or tools, while still allowing the levelling device to be used in various tile laying scenarios
2Adaptability or versatility
If multiple separate spacer and/or tab devices are used, then more functions can be provided, but the number of devices and complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated levelling device. The base provides spacing function, the vertical member provides alignment and wedge insertion function, and the frangible connection provides both structural support during installation and easy removal after setting. This merging eliminates the need for separate spacer and tab devices, reducing overall system complexity while maintaining full functionality
Solution Approach 2:
The levelling device is designed to perform multiple functions: it acts as a spacer to maintain tile spacing, a positioning tool to ensure proper alignment, a wedge holder to apply pressure during setting, and an easy-removal template after installation. This multi-functionality allows one device to replace several separate tools, improving ease of operation and reducing the number of components needed
3Ease of operation
If the frangible connection is positioned above the base or in incorrect positions, then the levelling device can be removed easily, but the connection does not break at the desired location and separation occurs in the wrong location
Solution Approach 1:
The frangible connection is pre-positioned at the rear end of the vertical member below the base, creating a predetermined break point before installation. This preliminary positioning ensures that when pressure is applied during tile setting, the connection will break at the correct location, preventing separation in wrong locations while maintaining ease of removal after installation
Data Source
AI summary
A levelling system for aligning surface coverings includes a tab with a substantially flat base and a vertical member extending away from a central area of the top surface of the base. The base includes beveled feet portions on opposite sides thereof to allow it to be more easily inserted under lower surfaces of adjacent surface coverings, with the vertical member extending between opposed edges or ends of the tiles. The vertical member is attached to the base by reduced width frangible leg portions held in rounded openings, below the top surface of the base. The vertical member includes an opening spaced so as to be above two adjacent tiles when the tiles are placed on the base on either side of the vertical member. When a wedge is inserted and held in the opening and presses down, the tiles are pushed downwardly toward a surface upon which they are being laid to properly align the edges thereof until the tiles are set, the wedge removed and the vertical member broken off at the frangible leg portions.