U.S. patent application number 10/850647 was filed with the patent office on 2005-11-24 for permanent tile spacer.
Invention is credited to Milam, Edward, Serros, Ron.
Application Number | 20050257468 10/850647 |
Document ID | / |
Family ID | 35373834 |
Filed Date | 2005-11-24 |
United States Patent
Application |
20050257468 |
Kind Code |
A1 |
Serros, Ron ; et
al. |
November 24, 2005 |
Permanent tile spacer
Abstract
A tile spacer for maintaining a substantially similar space
between laid tiles that is not removed and thus, remains a
permanent part of a tile installation. The preferred spacers have a
height of less than a height of an adjoining tile for providing a
space of grouting material. The preferred spacers are made from a
material that adheres to the tile adhesive or mastic, and also
adheres to the grouting material thus, the preferred material is
the adhesive material. The preferred spacer material also has
properties to maintain the size, configuration and integrity of the
spacer thus, substantially prohibiting the expansion or contraction
of the material due to temperature or humidity.
Inventors: |
Serros, Ron; (Albuquerque,
NM) ; Milam, Edward; (Albuquerque, NM) |
Correspondence
Address: |
DENNIS F ARMIJO
6300 MONTANO RD. NW
SUITE D
ALBUQUERQUE
NM
87120
US
|
Family ID: |
35373834 |
Appl. No.: |
10/850647 |
Filed: |
May 21, 2004 |
Current U.S.
Class: |
52/396.1 |
Current CPC
Class: |
E04F 15/08 20130101;
E04F 13/142 20130101; E04F 15/02022 20130101; E04F 15/02016
20130101 |
Class at
Publication: |
052/396.1 |
International
Class: |
E04H 012/34 |
Claims
What is claimed is:
1. A permanent spacer for providing a substantially uniform space
between tiles, the spacer comprising: a predetermined configuration
of said spacer comprising at least two radially extending legs and
a common junction wherein said at least two legs and said common
junction comprise a height of less than a thickness of the tiles;
and a material that adheres to an adhesive material underlaying the
tiles and a grout material and said material substantially
maintains its size and shape through varying thermal and moisture
conditions.
2. The invention of claim 1 wherein said material comprises said
adhesive material.
3. The invention of claim 1 where said material comprises a member
from the group consisting of thin set mortar, bonding mortar,
flexible bonding mortar, fortified thin-set mortar and a ceramic
tile adhesive.
4. The invention of claim 1 wherein said thickness of said spacer
comprises a thickness of one-half a thickness of the tiles.
5. A permanent spacer for providing a substantially uniform space
between at least two tiles, the spacer comprising: a predetermined
configuration wherein said predetermined configuration comprises a
means to maintain said substantially uniform space between the at
least two tiles; a height of said spacer comprising less than one
half of a thickness of the at least two tiles; and a material that
adheres to an adhesive material underlaying the at least two tiles,
the permanent spacer and a grout material and said material
substantially maintains its size and shape through varying thermal
and moisture conditions.
6. The invention of claim 5 wherein said predetermined
configuration comprises an I configuration.
7. The invention of claim 5 wherein said predetermined
configuration comprises a V configuration.
8. The invention of claim 5 wherein said predetermined
configuration comprises a T configuration.
9. The invention of claim 5 wherein said predetermined
configuration comprises an X configuration.
10. The invention of claim 5 wherein said material comprises said
adhesive material.
11. The invention of claim 5 where said material comprises a member
from the group consisting of thin set mortar, bonding mortar,
flexible bonding mortar, fortified thin-set mortar and a ceramic
tile adhesive.
12. The invention of claim 5 wherein said thickness of said spacer
comprises a thickness of one-half a thickness of the tiles.
13. A method of installing tiles with a permanent spacer, the
method comprising the steps of: a) applying an adhesive to a
surface to be tiled; b) laying first tile onto the adhesive; c)
placing a spacer adjacent to a first edge of the first tile, the
spacer comprising a height of less than a thickness of the tiles;
d) laying a second tile with a second edged adjacent to the spacer;
e) repeating steps a) through d) with a next tile and a next
spacer; f) allowing the adhesive to cure; and g) grouting a space
between the tiles and over the spacers.
14. The method of claim 13 wherein said surface to be tiled
comprises a vertical surface.
15. The method of claim 13 further comprising the step proving the
spacer made of an adhesive material.
16. The method of claim 15 wherein the adhesive material comprises
a member from the group consisting of thin set mortar, bonding
mortar, flexible bonding mortar, fortified thin-set mortar and a
ceramic tile adhesive.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention (Technical Field)
[0002] The invention relates to the installation of tile and more
particularly to permanently mounted tile spacers used for the
installation of tile.
[0003] 2. Background Art
[0004] For most tile installations, the surface to be tiled is
prepared and an adhesive material is applied to the prepared
surface. The initial tiles are then placed on the adhesive. Prior
to placing tiles adjacent to the tiles mounted on the surface most
installers apply a spacer. Presently, in tile installation, plastic
or rubber spacers or the like are used to keep the spacing between
tiles consistent. This same process is used for tiles installed on
a perpendicular surface as well as vertical surfaces. Once the
entire section is tiled, the adhesive under the tiles is allowed to
cure for a specified period of time. Then the installers must
remove the spacers. This task is very time consuming and can be
fairly difficult for most installers. Some spacers, like the ones
described in U.S. Pat. No. 4,953,341, contain protrusions that
provide a means for one to "kick" the spacer out, but most
installers require a screwdriver, or similar removal tool as
described in U.S. Pat. No. 5,010,654, to pry the spacer off the
adhesive for removal. One prior art method, as described in U.S.
Pat. 4,862,668, calls for setting the spacers on fire or burning
them to melt the spacers. Once the spacers are removed, the
grouting material is introduced into the valleys between the tiles
and a standard finishing process is performed. Another prior art
device is described in U.S. Pat. No. 5,363,560. This device is for
very large tiles and is designed to level the tiles to be
consistent with the adjoining tiles. A similar device is described
in U.S. Pat. No. 4,503,654. Each of these devices are very
expensive compared to the present invention and would be unuseable
on level floors. The present invention eliminates the step of
taking out the plastic or rubber spacers, which saves time and
labor. The new spacer does not require the spacer to be
removed.
SUMMARY OF THE INVENTION (DISCLOSURE OF THE INVENTION)
[0005] In accordance with the present invention, there is provided
an apparatus and method for using permanent spacers for maintaining
a substantially similar space between tiles. The preferred
permanent spacer for providing a substantially uniform space
between tiles comprises, a predetermined configuration of the
spacer comprising at least two radially extending legs and a common
junction wherein the at least two legs and the common junction
comprise a height of less than a thickness of the tiles and the
spacer comprises a material that adheres to an adhesive material
underlaying the tiles and a grout material and the material
substantially maintains its size and shape through varying thermal
and moisture conditions. The preferred spacer material comprises
the adhesive material. The preferred adhesive material comprises a
member from the group consisting of thin set mortar, bonding
mortar, flexible bonding mortar, fortified thin-set mortar and a
ceramic tile adhesive. The preferred thickness of the spacer
comprises a thickness of one-half of a thickness of the tiles.
[0006] The preferred permanent spacer for providing a substantially
uniform space between at least two tiles comprises a predetermined
configuration wherein the predetermined configuration comprises a
means to maintain the substantially uniform space between the at
least two tiles, a height of the spacer comprising less than one
half of a thickness of the at least two tiles and a material that
adheres to an adhesive material underlaying the at least two tiles,
the permanent spacer and a grout material, and the material
substantially maintains its size and shape through varying thermal
and moisture conditions. The predetermined configuration can
comprise an I configuration, a V configuration, a T configuration
or an X configuration. The preferred spacer material comprises the
adhesive material. The preferred spacer material comprises a member
from the group consisting of thin set mortar, bonding mortar,
flexible bonding mortar, fortified thin-set mortar and a ceramic
tile adhesive. The preferred thickness of the spacer comprises a
thickness of one-half a thickness of the tiles.
[0007] The preferred method of installing tiles with a permanent
spacer comprises the steps of applying an adhesive to a surface to
be tiled, laying first tile onto the adhesive, placing a spacer
adjacent to a first edge of the first tile, the spacer comprising a
height of less than a thickness of the tiles, laying a second tile
with a second edged adjacent to the spacer, repeating the above
steps with a next tile and a next spacer, allowing the adhesive to
cure and grouting a space between the tiles and over the spacers.
The preferred method of installing tiles using the permanent spacer
comprises installing tiles on a vertical surface. The preferred
method further comprises the step proving the spacer made of an
adhesive material. The preferred adhesive material comprises a
member from the group consisting of thin set mortar, bonding
mortar, flexible bonding mortar, fortified thin-set mortar and a
ceramic tile adhesive.
[0008] A primary object of the present invention is provide a tile
spacer that does not have to be removed.
[0009] Another object of the invention is to provide a tile spacer
that does not expand or contract due to temperature or
moisture.
[0010] A primary advantage of the present invention is that by
using the new tile spacer it saves the installer and consumer time,
cost, and labor, because the spacer is not removed.
[0011] Another advantage of the present invention is that the new
spacer maintains accurate spacing between tiles mounted on vertical
surfaces, such as walls.
[0012] Other objects, advantages and novel features, and further
scope of applicability of the present invention will be set forth
in part in the detailed description to follow, taken in conjunction
with the accompanying drawings, and in part will become apparent to
those skilled in the art upon examination of the following, or may
be learned by practice of the invention. The objects and advantages
of the invention may be realized and attained by means of the
instrumentalities and combinations particularly pointed out in the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated into and
form a part of the specification, illustrate several embodiments of
the present invention and, together with the description, serve to
explain the principles of the invention. The drawings are only for
the purpose of illustrating a preferred embodiment of the invention
and are not to be construed as limiting the invention. In the
drawings:
[0014] FIG. 1 is a perspective view of the preferred new tile
spacer.
[0015] FIG. 2 is a shows the new spacer installed between
tiles.
[0016] FIG. 3 is a perspective view of an installation of tiles
using the preferred spacer prior to grouting.
[0017] FIG. 4 is a perspective view of a completed installation of
tiles using the preferred spacer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS (BEST MODES FOR CARRYING
OUT THE INVENTION)
[0018] FIG. 1 shows the preferred configuration of the new spacer
10. This configuration is similar to the prior art rubber spacers,
a cross configuration or at least two radially extending legs 12
and a common junction 14. In addition to the cross configuration,
the spacers can be configured in an "I", "T" or "V" configuration,
depending on the particular style of tile or installation (not
shown). However, the new spacers are constructed from a material
that adheres to the mastic or adhesive that is spread onto the
surface prior to setting the tile. The preferred material also
preferably has the properties of not expanding or contracting or
expanding and contracting similarly to the adhesive or grout
material. Additionally, the preferred material does not absorb
moisture or expand, contract or degrade when exposed to moisture.
Thus, the preferred material for constructing the spacers is the
adhesive or mastic material. These include thin set mortar, bonding
mortar, flexible bonding mortar, fortified thin-set mortar, and
ceramic tile adhesives. By using one of the aforementioned
materials, the new spacer bonds to the adhesive material and the
grout. In addition, the spacer can be made of baked clay, concrete,
mortar, underlayment material with or without hardeners or any
other similar material that readily adheres to the adhesive
material.
[0019] As shown in FIGS. 2 and 3, spacer 10 is placed on adhesive
material 18 in between tiles 16, a method well known in the art.
Thus the tiles 16 and the spacer 10 are glued or adhered to the
adhesive material 18. The spacer 10, having uniform width radially
extending legs 12 provides for uniform spaces between the tiles 16
for an aesthetic appearance. The main feature of the inventive
spacer 10, is that they do not need to be removed like prior art
spacers. The removal of the prior art spacers is especially
difficult for smaller tile installations, such as using spacers for
providing one-eighth (1/8) inch. Spacer 10 has a preferable height
20 that is less than a height of the tile 22 for providing space
for grout 24. The preferred height 20 of the spacer 10 is
approximately one-half (1/2) the height of the tile 22. The new
spacers are especially useful for laying tile on vertical surfaces
such as wall. When installed on a vertical surface, gravity tends
to pull the tile down. This new advanced spacer keeps the tile
stable. Other spacers need to be removed, and when removed the tile
tends to sag down.
[0020] FIG. 4 is a perspective view of a final tile installation
using the new spacer 10. The tiles are installed as set forth
above. The final step of the process is the placement of grout
material 24 in the spaces between the tiles 26 and over the spacer
10 as shown. Due to the properties of the spacers 10, the grouting
material adheres to the spacer.
[0021] The spacers are preferably manufactured in mass quantities.
The preferred manufacturing process could include a mold where by
one or more spacers could be made by pouring or injecting the
spacer material onto the mold and letting the spacer material to
cure or harden. Variations would be different sizes, such as 1/8,
1/4, 1/2 or 1 inch. The spacers could be of different colors to
compliment the chosen grout color. For instance, for darker grout,
the spacers could be a gray color, and for lighter color grout the
spacers could be white.
[0022] Although the invention has been described in detail with
particular reference to these preferred embodiments, other
embodiments can achieve the same results. Variations and
modifications of the present invention will be obvious to those
skilled in the art and it is intended to cover in the appended
claims all such modifications and equivalents. The entire
disclosures of all references, applications, patents, and
publications cited above, are hereby incorporated by reference.
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