Tile-setting lippage and spacing control

Abstract

A tile-setting lippage and spacing control system and method for use with tiles set with mortar as floors or walls on prepared surfaces, providing spacing tabs each having a tab body with a tab opening to accommodate a wedge, a strengthened tab border, and a lower tab body meant to extend downward between tiles as a spacer. A foot unit having a footplate and footplate ridges is removably attached at the bottom of the lower tab body through tab-to-foot joins at the footplate ridges. In use, mortar is applied to a prepared surface. Tile is placed with spacing tabs placed into the grout-line gaps between tiles, with the footplate of the foot unit extending underneath both tiles and embedded in the mortar. The lower tab body extends upward between the tiles and sets the gap or grout line between the tiles. The tab body and strengthened tab border extend upward above the tops of the tiles. A wedge is pushed into the tab opening, placing downward pressure on the tops of the tiles while pulling upward against the foot unit locked underneath the tiles, creating a clamping force which holds the tops of the tiles level with each other. The tab-to-foot joins withstand the straight-line constant clamping force between the wedge and the foot unit during use, and then break when a sharp oblique force is applied, allowing removal from the gap between tiles without damage to the tiles. After the mortar cures and sets the spacing tab is removed by applying a sharp oblique force, tearing the tab body cleanly away from the foot unit which remains embedded in mortar underneath the tiles.

We claim: 
     
         1 . A tile-setting lippage and spacing control system for use with tiles set with mortar as floors or walls on prepared surfaces, the tile-setting lippage and spacing control system comprising:
 (i) a spacing tab adapted to set a spacing between tiles, having two opposing faces oriented along the gap between tiles, and having a tab body having an upper and lower orientation with a lower tab body extending downward between the tiles, and with a strengthened tab border surrounding the upper portion of said tab body, and having a tab opening in said tab body;   (ii) a foot unit having a footplate having footplate ridges, removably attached to the lowest edge of said lower tab body through tab-to-foot joins at each said footplate ridge; and   (iii) a wedge adapted to fit said tab opening;   where, in use, said spacing tab with attached said foot unit is placed between tiles being set into uncured mortar, setting the size of the gap between tiles, and with both tiles being clamped between said wedge placed through said tab opening at the top of the tiles and the foot unit at the bottom; and   where, in use, said spacing tab can be separated from said foot unit at said tab-to-foot joins by application of a sharp oblique force to said strengthened tab border, and can be removed from the gap between tiles without damage to the tiles.   
     
     
         2 . The tile-setting lippage and spacing control system of  claim 1 , where said spacing tab is further made of a plastic material. 
     
     
         3 . The tile-setting lippage and spacing control system of  claim 1 , where said spacing tab is further made of a recyclable plastic material. 
     
     
         4 . The tile-setting lippage and spacing control system of  claim 1 , where said spacing tab is further made of high-density polyethelene. 
     
     
         5 . The tile-setting lippage and spacing control system of  claim 1 , where said spacing tab is further adapted for re-use as a spacer in later tile installations. 
     
     
         6 . The tile-setting lippage and spacing control system of  claim 1 , where said lower tab body further comprises flat faces. 
     
     
         7 . The tile-setting lippage and spacing control system of  claim 1 , where said lower tab body further comprises concave faces. 
     
     
         8 . The tile-setting lippage and spacing control system of  claim 1 , where said lower tab body further comprises micropoint structures. 
     
     
         9 . A tile-setting lippage and spacing control system for use with tiles set with mortar as floors or walls on prepared surfaces, the tile-setting lippage and spacing control system comprising a lippage-control unit adapted to hold the top edges of adjacent tiles level with each other and to set the spacing between tiles during installation and setting of the mortar, comprising:
 (i) a spacing tab adapted to set a spacing between tiles, having two opposing faces oriented along the gap between tiles, and having a tab body having an upper and lower orientation with a lower tab body extending downward between the tiles, and with a strengthened tab border surrounding the upper portion of said tab body, and having a tab opening in said tab body;   (ii) a foot unit having a footplate having footplate ridges, removably attached to the lowest edge of said lower tab body through tab-to-foot joins at each said footplate ridge; and   (iii) a wedge adapted to fit said tab opening;   where, in use, said spacing tab with attached said foot unit is placed between tiles being set into uncured mortar, with said micropoint structures setting the size of the gap between tiles, and with both tiles being clamped between said wedge placed through said tab opening at the top of the tiles and the foot unit at the bottom; and   where, in use, said spacing tab can be separated from said foot unit at said tab-to-foot joins by application of a sharp oblique force to said strengthened tab border, and can be removed from the gap between tiles without damage to the tiles.   
     
     
         10 . A tile-setting lippage and spacing control method comprising:
 (i) providing a tile-setting lippage and spacing control system comprising:
 (a) a spacing tab adapted to set a spacing between tiles, having two opposing faces oriented along the gap between tiles, and having a tab body having an upper and lower orientation with a lower tab body extending downward between the tiles, and with a strengthened tab border surrounding the upper portion of said tab body, and having a tab opening in said tab body; 
 (b) a foot unit having a footplate having footplate ridges, removably attached to the lowest edge of said lower tab body through tab-to-foot joins at each said footplate ridge; and 
 (c) a wedge adapted to fit said tab opening; 
   (ii) applying mortar to the prepared surface;   (iii) placing said spacing tab between two adjacent tiles, setting the size of the gap between tiles;   (iv) placing said wedge through said tab opening, with the tiles being clamped between said wedge and said foot unit;   (v) allowing curing and setting of the mortar,   (vi) removing said spacing tab from the grout joint by application of a sharp oblique force; and   (vii) grouting the grout joint.