Wedge Leveling System for Tile Alignment
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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 proper alignment and alignment maintenance during the setting process.
Innovation Solution
A wedge leveling system featuring a tab with a base and vertical member, where the vertical member is held between tiles and a wedge is inserted to press down on the tiles, allowing for easy alignment and secure attachment until set, with frangible connections for easy removal after the adhesive sets, reducing the need for separate spacers and ensuring correct breaking points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If frangible connections are positioned in or above the base at different positions relative to side edges of tiles, then the wedge can be inserted to press tiles down, but the device does not provide consistent alignment results and requires additional spacers
Solution Approach 1:
The levelling device is segmented into distinct functional zones: the base positioned below tiles, vertical members extending upward between tile edges, and frangible connections positioned below the base. This segmentation allows each component to perform its specific function independently, with the base providing positioning, vertical members providing alignment reference, and frangible connections enabling controlled removal without interfering with tile alignment consistency.
Solution Approach 2:
The frangible connections are pre-positioned below the base at specific locations before the levelling device is installed. This preliminary positioning ensures that when the wedge is inserted and tiles are pressed down, the alignment is maintained consistently. After adhesive sets, the frangible connections break automatically, allowing easy removal of vertical members without requiring additional spacers or tools.
2Ease of operation
If frangible connections are positioned in or above the base, then the wedge can be inserted through the opening, but the connections do not break at the desired position and require additional tools for removal
Solution Approach 1:
The frangible connections are designed to break automatically at the desired position below the base after the adhesive sets. This self-service mechanism eliminates the need for additional tools or complex removal procedures. The connections are positioned and structured to fail at the correct location, allowing vertical members to be easily removed from between the tiles without requiring spacers, hammers, or other specialized tools.
3Reliability
If the vertical member extends between tile edges with frangible connections above the base, then alignment can be maintained, but the device is expensive and does not provide acceptable results without additional spacers
Solution Approach 1:
The levelling device is designed as a universal system where the base, vertical members, and frangible connections work together as an integrated multi-functional unit. The base provides positioning below tiles, vertical members provide alignment reference between tile edges, and frangible connections provide automatic removal capability. This universal design eliminates the need for separate spacer devices, making the system more reliable and cost-effective while maintaining consistent alignment throughout the tiling process.
Data Source
AI summary
A wedge 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 for insertion under lower surfaces of adjacent surface coverings, with the vertical member extending between the tiles. The vertical member is attached to the base with frangible leg. The vertical member includes an opening spaced so as to be above two adjacent tiles. 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.