INTEGRALLY FABRICATED TILE-LEVELING BASE AND WEDGE

A tile-leveling base and wedge are integrally fabricated. The base includes a tile-supporting platform. A base post including post proximal and distal ends has its proximal end attached to the tile-supporting platform at a first breakaway joint. A cross member perpendicularly depends from the post distal end and includes a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform and (ii) pivotable at the first breakaway joint into a position in which it is spaced apart from, and facing, the platform. The wedge includes a wedge tip, which tip, at the time of contemporaneous fabrication with the base, is attached to the base at a second breakaway joint so that the wedge can be separated from the base for use in combination with the base.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS/PRIORITY CLAIMS

The present application is a continuation-in-part application of International Application Serial No. PCT/US2018/054692 filed Oct. 5, 2018 pursuant to the Patent Cooperation Treaty, and under the title “INTEGRALLY FABRICATED TILE-LEVELING BASE AND WEDGE.” Application PCT/US2018/054692 claimed priority benefits in U.S. Provisional Application No. 62/568,646 filed Oct. 5, 2017 under the title “ONE PIECE FLOOR OR WALL TILE, LEVELING SYSTEM” and U.S. Provisional Application No. 62/584,889 filed Nov. 12, 2017 under the title “INTEGRALLY FABRICATED TILE-LEVELING BASE AND WEDGE.”

The present application claims the benefit of the filing dates of U.S. Provisional Application Ser. Nos. 62/568,646 and 62/584,889, as well as the filing date of PCT Application No. PCT/US2018/054692, based on the priority chain outlined above. Moreover, the entireties of the disclosures, including the drawings, of all three previous applications in the aforesaid priority chain are incorporated herein by reference as if set forth fully in the present application.

BACKGROUND

A key objective of a quality floor or wall tile installation is ensuring that at every joint at which adjacent tiles meet, the tiles are evenly spaced and mutually level (i.e., coplanar). Depending on the layout and location of tiles within a titled space, two or four tiles may meet at a common joint, for example. Ideally, all tiles over a particular tiled area should extend along a common tile plane with no discernable deviation in heights of the tiles' upper surfaces (i.e., the surfaces visible to observers after installation).

Various apparatus and devices have been devised to aid in the leveling of tiles during installation. One common system includes a cooperating combination of tile-leveling bases and wedges. One example of such a base and wedge leveling system is produced by QEP, and sold under the tradename “LASH,” which is an acronym for “level, align, space, and hold.” Several manufacturers, including QEP, refer to as “clips” the structures introduced above as “bases.” Throughout the remainder of the present specification, as well as the claims, the term “base” or “tile-leveling base” is employed, as well as their plural forms, “bases” and “tile-leveling bases.” Although the specific configurations of the tile-leveling bases and wedges may vary among types and manufactures, the various tile-leveling bases and wedges have in common certain general elements.

A tile-leveling base includes a tile-supporting platform configured to extend, when deployed, along the tile plane and below the lower surfaces of two or more adjacent tiles. Extending perpendicularly to the tile-supporting platform is a base post. The base post extends for a predetermined distance away from the tile-supporting platform toward a post distal end. Extending perpendicularly from the base post is at least one cross member, each of which cross members includes at least one wedge-engaging surface spaced apart by a predetermined distance from, and facing, the base platform. The predetermined distance by which the base platform and the wedge-engaging surface are spaced apart is preconfigured to be larger than the thickness of the tiles with which that particular tile-leveling base is to be used. In this way, in the case of floor tile, for example, when the tile lower surfaces of adjacent tiles are resting on the base platform, there is defined a wedge gap between each tile upper surface and the wedge-engaging surface.

A wedge for use in combination with the tile-leveling base includes wedge bottom and top surfaces. The wedge bottom surface extends longitudinally between a wedge heel and wedge tip, and is configured for contactably engaging and sliding across tiles' upper surfaces. The wedge top surface also extends longitudinally between the wedge heel and tip, and along a plane nonparallel to the wedge bottom surface such that the wedge bottom and top surfaces mutually converge to define the wedge tip.

For purposes of understanding, use of a tile-leveling base and wedge is briefly described in the context of tiling a floor, as opposed to a wall, and even then only by way of non-limiting example. With a first of two tiles situated on top of still-wet setting material (e.g., mortar), a portion of the tile-supporting platform of a tile-leveling base is inserted under the tile lower surface of that first tile with the base post protruding upwardly above the tile upper surface. Next, with enough still-wet setting material spread adjacent the first tile to accommodate a second tile, the second tile is situated adjacent the first tile, with the tile lower surface of that second tile resting over a portion of the tile-supporting platform on the opposite side of the base post from the portion of the tile-supporting platform supporting the first tile. Moreover, the first and second tiles are adjacently situated such that there is defined between them a tile gap, which is later filled with grout.

With the base post extending upwardly through the tile gap between the first and second tiles, a wedge is aligned with and slidably inserted into the wedge gap defined between each tile upper surface and the wedge-engaging surface of the cross member. As the wedge is urged into the wedge gap in a direction perpendicular to the tile gap, and along the tile upper surfaces of the first and second tiles, the wedge top surface eventually engages the wedge-engaging surface of the cross member extending perpendicularly from the base post. When the wedge is thusly urged from the wedge heel with sufficient force, the cross member “rides” up the wedge top surface, thereby applying an upwardly directed tensile force to the base post and urging the base platform toward and against the tile lower surfaces. At the same time, the wedge bottom surface is being urged downwardly with equal and opposite force against the tile upper surfaces. Because the wedge bottom surface defines a single plane, the tile upper surfaces of the first and second tiles are brought into planar alignment along the tile gap defined between the first and second tiles.

Once the setting material cures (i.e., dries) and the titles are set, the base post is broken away from the tile-supporting platform. This step is most frequently achieved by striking the base post with a rubber mallet or kicking it with a work shoe substantially along—and not across—the tile gap defined between the adjacent tiles. The base post is designed to break away from the tile-supporting platform—which is permanently set in place under the adjacent tiles—at a location below the tile upper surfaces so that, when gap-filling grout is applied between the tiles, no remaining portion of the tile-leveling base is visible.

Presently, tile-leveling bases are manufactured, packaged and sold separately from the wedges suitable for use with those wedges. On the manufacturing and distribution side, this fact requires separate fabrication, packaging, and display at retail of the bases and wedges. On the consumer side, care must be taken to match tile-leveling bases with properly sized wedges.

Accordingly, a need exists for a tile-leveling base and wedge that are integrally formed at the time of fabrication, but configured for ready on-site separation by a tile installer.

SUMMARY

In each of various embodiments, a tile-leveling base and wedge for use with the base are contemporaneously and integrally fabricated. The manner in which the wedge and base are integrally formed may vary, as the particular method of manufacture is not central to various aspects of the invention. Although injection molding is regarded as a particularly advantageous option, alternative molding techniques, or even 3D printing, are possibilities within the scope and contemplation of the invention.

The tile-leveling base includes a tile-supporting platform with opposed platform top and bottom sides bounded by a platform periphery. A base post includes post proximal and distal ends. The tile-supporting platform and base post are formed at manufacture such that the post proximal end is attached to the tile-supporting platform by and at a first breakaway joint with a predetermined first tensile strength and a predetermined first shear strength.

At least one cross member depends from, and extends perpendicularly to, the post distal end. Most commonly, the cross member will simply be integrally formed as a portion of the base post itself, while also having certain discernable elements including a cross-member distal edge facing away from the tile-supporting platform. Additionally, the cross member includes at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform top side and (ii) movable into a position in which it is spaced apart by a predetermined distance from, and facing, the platform top side.

The wedge extends longitudinally along a wedge axis between a wedge heel and a wedge tip. A wedge bottom surface and an opposed wedge top surface coextend longitudinally along the wedge axis. The wedge bottom and top surfaces generally extend along respective non-parallel planes such that they mutually converge to define the wedge tip. In some embodiments, the wedge top surface is undulated in a manner defining, for example, a saw tooth or stepped profile. The reason for this will be readily appreciated by practitioners of the tile-installation profession, and even “do-it-yourself” homeowners: such a surface allows the wedge, when in use with the tile-leveling base, to engage the wedge-engaging surface in increments and “click” as it is advanced between the wedge-engaging surface and tile upper surfaces.

As fabricated, various embodiments are configured such that the wedge tip is attached to the cross-member distal edge at a second breakaway joint with a predetermined second tensile strength and a predetermined second shear strength. The second breakaway joint facilitates selective separation for use of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base. Although, in alternative versions, the wedge tip may instead be attached by a second breakaway joint to the platform periphery, attachment of the wedge tip to the cross-member distal edge of various embodiments facilitates particular methods of use later described.

In accordance with at least one variation, the first breakaway joint by which the base post proximal end is attached to the tile-supporting platform is a living hinge. The living hinge is configured such that the base post is pivotable relative to the tile-supporting platform between post first and second attitudes. In the post first attitude, the base post is substantially coplanar with the tile-supporting platform, while, in the post second attitude, the base post extends perpendicularly to the tile-supporting platform in a direction upwardly of the platform top side. It is to be understood that “upwardly” as used in the preceding sentence is a relative term; while the tile-leveling base may be oriented in any number of orientations in space, a “common-vernacular definition” of “upwardly” in this case indicates that, in the post second attitude, the base post protrudes away from the tile-supporting platform in the same direction that the platform top side faces.

At the time that each of various embodiments is fabricated, the base post and tile-supporting platform are formed with the base post in the post first attitude. In such instances, the post first attitude may be alternatively referred to as the “fabrication attitude.” In contrast, in order to deploy the pivotable base post for use, the base post must be pivoted into or toward the post second attitude. For this reason, the post second attitude may be alternatively referred to as the “deployed attitude.”

Once the tile-leveling base and wedge are separated from one another, and the base post is in the deployed attitude, the tile-leveling base and wedge may be used in a manner consistent with the manner in which extant tile-leveling bases and wedges are used. Accordingly, the explanation of the use of bases and wedges provided in the background is relied upon to provide the explanation and disclosure as to how the tile-leveling based and wedges of the present invention are employed on a tiling job.

When a user uses an embodiment of the tile-leveling base and wedge in substantially the same manner as existing, separately fabricated bases and wedges, (s)he tears the wedge from the base at the second breakaway joint before setting the base platform under two adjacent tiles. For such uses, it matters little whether, at the time of fabrication, the wedge tip is attached to the tile-leveling base at the platform periphery or the cross-member distal edge. However, certain particular methods of use implementable only in association with wedges and tile-leveling bases integrally fabricated in general accordance with the present invention specifically require fabrication with the wedge tip attached to the cross-member distal edge.

According to one method of leveling title, there is provided an integrally fabricated wedge and tile-leveling base as generally described above, but specifically wherein the wedge tip is attached to the cross-member distal edge. Moreover, in order to facilitate the method, at least one of the following parameters is met relative to the first and second breakaway joints associated with, respectively, (a) the attachment between the post proximal end and the tile-supporting platform and (b) the attachment between the wedge tip and the cross-member distal edge: (i) the first tensile strength is greater than the second tensile strength and (ii) the first shear strength is greater than the second shear strength. More generally, the idea is that, prior to the separation of any integrally formed elements, the connection between the wedge tip and the cross-member distal edge be weaker than the connection between the base post and the tile-supporting platform so that the wedge separates more easily from the cross-member distal edge than the base post separates from the tile-supporting platform.

According to the illustrative method, adjacent tiles are placed with their tile lower surfaces resting on the same tile-supporting platform and with a tile gap defined between them, as generally described above. However, at this point in the method, the wedge is still attached to the cross-member distal edge of base post extending upwardly between and above the tile upper surfaces. With the tile-setting material still wet, a tile installer pulls up on the wedge, using it as a kind of handle, to urge the tile-supporting platform toward the tile lower surfaces and preliminarily level the tiles.

Following the preliminary leveling, the installer separates the wedge from the cross-member distal edge of the base post. This separation may be done by a tearing action which could entail applying to the wedge at least one of (a) tensile force and (b) shear force of sufficient magnitude to cause failure of (i.e., break) the second breakaway joint at which the wedge tip and cross-member distal edge are joined. It is envisioned that a shear force sufficient to break the second breakaway joint may be applied by a user's grasping and twisting the wedge about the wedge axis in either a clockwise or counterclockwise direction relative to the tile plane. At this point, it is important that the applied force cause the second breakaway joint, and not the first breakaway joint, to fail; if the first breakaway joint fails at this stage, the base post will no longer be attached to the tile-supporting platform, and the wedge will be rendered useless. Following removal of the wedge, the tile-leveling base and wedge are then used in substantially the traditional manner previously described to finalize the tile leveling before the tile-setting material permanently sets the tiles.

Representative embodiments are more completely described and depicted in the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tile-leveling base and wedge integrally formed;

FIG. 2 is a side view of the tile-leveling base and wedge of FIG. 1 showing the base post in a post first attitude relative to the tile-supporting platform of the tile-leveling base;

FIG. 3 is a second perspective view of the tile-leveling base and wedge of FIGS. 1 and 2 in which—with the wedge and tile-leveling base still joined—the base post has been pivoted relative to the tile-supporting platform from the post first attitude to a second post attitude in which the base post extends perpendicularly to the tile-supporting platform;

FIG. 4 presents a side view of the still-joined tile-leveling base and wedge of FIGS. 1-3 and the base post in the second post attitude;

FIG. 5 is a perspective view of the tile-leveling base and wedge of FIGS. 1-4 after they have been separated from one another and positioned for use;

FIG. 6 is a side view showing of the same relative arrangement of the now-separated tile-leveling base and wedge in the same relative arrangement in which they are depicted in FIG. 5; and

FIG. 7 shows a plurality of tile-leveling base and wedge sets stacked for packaging.

DETAILED DESCRIPTION

The following description of variously embodied tile-leveling bases and wedges is demonstrative in nature and is not intended to limit the invention or its application of uses. Accordingly, the various implementations, aspects, versions and embodiments described in the summary and detailed description are in the nature of non-limiting examples falling within the scope of the appended claims and do not serve to restrict the maximum scope of the claims.

With conjunctive reference to FIGS. 1-6, components of an illustrative tile-leveling base and wedge set 10 are shown and described. As depicted throughout the drawings, the tile-leveling base and wedge system 10 includes two main elements: (i) a tile-leveling base 100 and (ii) wedge 200 configured to cooperate with that tile-leveling base 100. As an initial observation, FIGS. 1-4 show the title-leveling base 100 and wedge 200 as joined (integrally formed) in their manufactured state, while FIGS. 5 and 6 show the tile-leveling base 100 and wedge 200 separated from one another, but generally positioned relative to one another in a cooperative state for leveling tiles. Each of the two main elements is the subject of detailed discussion below in conjunction with referenced drawings.

Throughout the drawings, like reference characters are used to denote like elements, regardless of whether a particular reference character is called out with reference to a particular figure in the present description. Although the major sub-elements of the tile-leveling base 100 and wedge 200 are visible in all of the drawings, they are introduced with initial reference to FIGS. 1 and 2.

The tile-leveling base 100 includes a tile-supporting platform 115 with opposed platform top and bottom sides 120 and 130 bounded by a platform periphery 135. A base post 150 includes post proximal and distal ends 152 and 154. The post proximal end 152 is attached to the tile-supporting platform 115 by a first breakaway joint JB1.

The first breakaway joint JB1 is configured to possess a predetermined first tensile strength and a predetermined first shear strength. More specifically, as will be appreciated by practitioners of the tile installation profession familiar with the tile-leveling bases of existing base and wedge systems, the first breakaway joint JB1 should have a sufficiently high tensile strength to withstand a force sufficient to draw adjacent tiles into a coplanar alignment as the wedge 200 is used to exert an upwardly directed tensile force on the base post 150. On the other hand, the shear strength of the first breakaway joint JB1 must be sufficiently low to facilitate removal of the base post 150 from between the two adjacently aligned tiles once the tile-setting material has set. The removal of these posts is most commonly achieved by a person's kicking them or impacting them with a tool, such as a rubber mallet, that will not damage the installed tile. These parameters and steps are so ubiquitously understood by tile installers that further explanation of them is unwarranted.

Depending from the post distal end 154 is at least one cross member 160. As in the example shown, in most configurations, the cross member 160 is integrally formed as an extension of the base post 150. The cross member 160 includes a cross-member distal edge 162 facing away from the tile-supporting platform 115. Moreover, on a cross-member proximal edge 163 generally opposite the cross-member distal edge 162 there is at least one wedge-engaging surface 164. In the particular embodiment shown, the base post 150 and cross member 160 form a substantially T-shaped structure that defines two wedge-engaging surfaces 164. However, alternative configurations are within the scope and contemplation of the invention such as, for example, a dual base post with a cross member that bridges a single wedge-accommodating gap defined between the dual base posts and the cross member.

In the illustrative, non-limiting configuration shown and described, the first breakaway joint JB1 is a living hinge HL configured such that the base post 150 is pivotable relative to the tile-supporting platform 115 between post first and second attitudes. In the post first attitude, shown in FIGS. 1 and 2, the base post 150 is substantially coplanar with the tile-supporting platform 115. In more common parlance, the base post 150 “lies flat” along the tile-supporting platform 115. Comparatively, as shown in FIGS. 3 and 4, when in the post second attitude, the base post 150 extends perpendicularly to the tile-supporting platform 115 in a direction upwardly of the platform top side 120. In pivoting between the post first and second attitudes, the base post subtends an angle of substantially 90°. With the benefit of conjunctive reference to FIGS. 1-4, it is more readily appreciated why the post first and second attitudes are alternatively referred to as, respectively, the “fabrication” and “deployed” attitudes. As molded in an injection mold, for example, the tile-leveling base 100 and wedge 200 are in substantially the configuration shown in FIGS. 1 and 2; that is, with the base post 150 in the post first attitude. To use the tile-leveling base 100, the base post 150 is pivoted to the post second attitude, or, the “deployed attitude.”

Referring now to the other principal component, the wedge 200 extends longitudinally along a wedge axis AW between a wedge heel 210 and a wedge tip 220. A wedge bottom surface 240 and a wedge top surface 260 longitudinally coextend forwardly of the wedge 210 heel and converge to define the wedge tip 220. In the illustrative version depicted, the wedge top surface 260 is undulated in a manner defining a saw tooth or stepped profile, which serves the purpose explained in the summary.

The depicted version of the tile-leveling base and wedge set 10 is configured such that the wedge tip 220 is attached to the cross-member distal edge 162 at a second breakaway joint JB2 configured to possess a predetermined second tensile strength and a predetermined second shear strength. The second breakaway joint JB2 facilitates selective separation for use of the wedge 200 from the tile-leveling base 100 without function-defeating damage to either one of the wedge 200 and tile-leveling base 100. As noted in the summary, in an alternative version, the wedge tip 220 may be joined to the tile-leveling base 100 by the second breakaway joint JB2 along the platform periphery 135. Because the scenario in which the wedge tip 220 is attached at the cross-member distal edge 162 is shown, and the relocation of the second breakaway joint JB2 to the platform periphery 135 can be readily envisioned, this latter arrangement is adequately disclosed, supported, and within the scope of the claims appended hereto unless claims language otherwise explicitly excludes it.

As explained in the summary, a particular subset of embodiments in which the second breakaway joint JB2 joins the wedge tip 220 to the cross-member distal edge 162 facilitates certain tile-leveling method steps not associated with traditional methods of installation involving separately available wedges and tile-leveling bases. While these illustrative method steps were discussed in the summary in terms sufficiently clear and complete to enable a person of ordinary skill in the related trades—or even untrained homeowners—to implement them, they are further elucidated with principal reference to FIGS. 3 and 4.

In FIGS. 3 and 4, the still-attached wedge 200 and tile-leveling base 100 are shown in an orientation in which they would be when adjacent tiles are placed with their tile lower surfaces resting on the same tile-supporting platform 115 and with a tile gap defined between them. While illustrative tiles are not shown in FIGS. 3 and 4, there placement can be readily imagined, a fact that renders specific illustration of same unnecessary. Moreover, illustrative tiles—tile 1 and tile 2—are shown in FIG. 6 in the way they would be placed relative to the tile-leveling base 100 even before separation of the wedge 200.

Referring once again to FIGS. 3 and 4, at this point in the method, the wedge 200 is still attached to the cross-member distal edge 162 of the base post 160 extending upwardly between and above the tile upper surfaces (again, see FIG. 6 for a visual of the tile upper surfaces). With the tile-setting material still wet, a tile installer pulls up on the wedge 200, using it as a kind of handle, to urge the tile-supporting platform 115 toward the tile lower surfaces. This action preliminarily levels the tiles, before the wedge 200 is separated.

Following the preliminary tile leveling, the installer separates the wedge 200 from the cross-member distal edge 162 of the base post 160. This separation may be done by a tearing action which could entail applying to the wedge 200 at least one of (a) tensile force and (b) shear force of sufficient magnitude to cause failure of the second breakaway joint JB2 at which the wedge tip 200 and cross-member distal edge 162 are attached. It is envisioned that a shear force sufficient to break the second breakaway joint JB2 may be applied by a user's grasping and twisting the wedge 200 about the wedge axis AW in either a clockwise or counterclockwise direction relative to the tile plane. At this point, it is important that the applied force cause the second breakaway joint JB2, and not the first breakaway joint JB1, to fail; if the first breakaway joint fails JB1 at this stage, the base post 160 will no longer be attached to the tile-supporting platform 115, thereby rendering useless for subsequent steps the base post 160 and the wedge 200.

FIGS. 5 and 6 show the tile-leveling base 100 and the wedge 200 after they have been separated and are generally situated for use. Tiles are not shown in FIG. 5 so that the relative positions of the tile-leveling base 100 and the wedge 200 can be seen unobstructed. In the side cross-sectional view, however, the tile-leveling base 100 and the wedge 200 are shown in situ relative to first and second tiles (“tile 1” and “tile 2”) to be rendered coplanar by the tile-leveling base and wedge set 10 in the general manner explained in the background with respect to existing tiling-leveling bases and wedges.

The benefits of integral fabrication of a tile-leveling base 100 and wedge 200 are several. In addition to facilitating the execution of certain installation methods described above, integral fabrication facilitates production, distribution, and sale of a tile-leveling base 100 and appropriately-sized, matching wedge 200 in a single step. At the retailer and user ends, there is assured a matching quantity of bases 100 and wedges 200 on display for sale and on a jobsite. An additional advantage of integral fabrication in a manner described in association with some aspects (e.g., wherein the base post 150 lays flat along the tile-supporting platform 115) is that stacking of plural tile-leveling base and wedge sets 10 is facilitated. FIG. 7 illustratively depicts a plurality of tile-leveling base and wedge sets 10 with the base post 150 of each in the preferred “fabrication attitude,” and the wedge 200 of each still attached to its respective tile-leveling base 100. A stack such as that in FIG. 7 could then be packaged for sale.

The foregoing is considered to be illustrative of the principles of the invention. Furthermore, since modifications and changes to various aspects and implementations will occur to those skilled in the art without departing from the scope and spirit of the invention, it is to be understood that the foregoing does not limit the invention as expressed in the appended claims to the exact constructions, implementations and versions shown and described.

Claims

1. A tile-leveling base and wedge integrally fabricated and comprising:

a tile-leveling base including a tile-supporting platform with opposed platform top and bottom sides bounded by a platform periphery;
a base post including post proximal and distal ends, the post proximal end being attached to the tile-supporting platform by and at a first breakaway joint;
at least one cross member depending from, and extending perpendicularly to, the post distal end and including a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform top side and (ii) movable into a position in which it is spaced apart by a predetermined distance from, and facing, the platform top side; and
a wedge extending longitudinally along a wedge axis between a wedge heel and a wedge tip, the wedge including a wedge bottom surface and a wedge top surface that coextend longitudinally along the wedge axis and mutually converge to define the wedge tip; wherein,
(i) the wedge tip is attached to the cross-member distal edge at a second breakaway joint in order to facilitate selective separation of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base; and
(ii) the second breakaway joint is weaker than the first breakaway joint such that the wedge separates more easily from the cross-member distal edge than the base post separates from the tile-supporting platform.

2. The tile-leveling base and wedge of claim 1 integrally fabricating by injection molding.

3. The tile-leveling base and wedge of claim 1 wherein the first breakaway joint by which the base post is attached to the tile-supporting platform is a living hinge such that the base post is pivotable relative to the tile-supporting platform between a post first attitude in which the base post is substantially coplanar with the tile-supporting platform and a post second attitude in which the base post extends perpendicularly to the tile-supporting platform in a direction upwardly of the platform top side.

4. The tile-leveling base and wedge of claim 3 wherein the base post and tile-supporting platform are formed at the time of fabrication with the base post in the post first attitude.

5. A tile-leveling base and wedge integrally fabricated and comprising:

a tile-leveling base including a tile-supporting platform with opposed platform top and bottom sides bounded by a platform periphery;
a base post including post proximal and distal ends, the post proximal end being attached to the tile-supporting platform by and at a first breakaway joint;
at least one cross member depending from, and extending perpendicularly to, the post distal end and including a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is at least one of (i) spaced apart by a predetermined distance from, and facing, the platform top side and (ii) movable into a position in which it is spaced apart by a predetermined distance from, and facing, the platform top side; and
a wedge extending longitudinally along a wedge axis between a wedge heel and a wedge tip, the wedge including a wedge bottom surface and a wedge top surface that coextend longitudinally along the wedge axis and mutually converge to define the wedge tip; wherein,
the wedge tip is attached to the tile-leveling base at a second breakaway joint in order to facilitate selective separation of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base.

6. The tile-leveling base and wedge of claim 5 wherein the base post and tile-supporting platform are formed at the time of fabrication with the wedge tip attached to the cross-member distal edge by the second breakaway joint.

7. The tile-leveling base and wedge of claim 6 wherein

(i) the first breakaway joint by which the base post is attached to the tile-supporting platform is a living hinge such that the base post is pivotable relative to the tile-supporting platform between a post first attitude in which the base post extends substantially along the tile-supporting platform and a post second attitude in which the base post extends perpendicularly to the tile-supporting platform in a direction upwardly of the platform top side; and
(ii) the second breakaway joint is weaker than the first breakaway joint such that the wedge separates more easily from the cross-member distal edge than the base post separates from the tile-supporting platform when there is applied to the wedge at least one of (a) tensile force and (b) shear force of sufficient magnitude to cause failure of the second breakaway joint at which the wedge tip and cross-member distal edge.

8. The tile-leveling base and wedge of claim 7 wherein the base post and tile-supporting platform are formed at the time of fabrication with the base post in the post first attitude.

9. The tile-leveling base and wedge of claim 8 integrally fabricating by injection molding.

10. The tile-leveling base and wedge of claim 7 integrally fabricating by injection molding.

11. The tile-leveling base and wedge of claim 6 integrally fabricating by injection molding.

12. A tile-leveling base and wedge integrally fabricated and comprising:

a tile-leveling base including a tile-supporting platform with opposed platform top and bottom sides bounded by a platform periphery;
a base post extending perpendicularly to the tile-supporting platform and including post proximal and distal ends, the post proximal end being attached to the tile-supporting platform by and at a first breakaway joint possessing a predetermined first tensile strength and a predetermined first shear strength;
at least one cross member depending from, and extending perpendicularly to, the post distal end and including a cross-member distal edge facing away from the tile-supporting platform and at least one wedge-engaging surface that is spaced apart by a predetermined distance from, and facing, the platform top side; and
a wedge extending longitudinally along a wedge axis between a wedge heel and a wedge tip, the wedge including a wedge bottom surface and a wedge top surface that coextend longitudinally along the wedge axis and mutually converge to define the wedge tip; wherein,
(i) the wedge is attached to the cross-member distal edge of the tile-leveling base at a second breakaway joint in order to facilitate selective separation of the wedge from the tile-leveling base without function-defeating damage to either one of the wedge and tile-leveling base;
(ii) the second breakaway joint possesses a predetermined second tensile strength and a predetermined second shear strength; and
(iii) at least one of (a) the first tensile strength is greater than the second tensile strength and (b) the first shear strength is greater than the second shear strength such that the wedge separates more easily from the cross-member distal edge than the base post separates from the tile-supporting platform.

13. The tile-leveling base and wedge of claim 12 integrally fabricating by injection molding.

Patent History
Publication number: 20200318364
Type: Application
Filed: Apr 6, 2020
Publication Date: Oct 8, 2020
Inventor: Giancarlo Giannunzio (Westminster, MA)
Application Number: 16/841,130
Classifications
International Classification: E04F 21/00 (20060101); E04F 21/22 (20060101);