Methods and systems for pattern oriented tile installation

Abstract

Systems and methods for pattern-oriented tile installation are herein provided. In one example, a tile installation system comprises a tile setting device comprising: an array module comprising suction cups; a control module coupled to the array module and configured to provide vacuum activation to the suction cups; a tile dispensing system comprising tiles stacked in layers; and a computing device configured to: determine one or more installation parameters; determine, based on the one or more installation parameters, a pattern specific code; determine, based on the pattern specific code, a suction cup configuration for the tile setting device, wherein: the tile dispensing system is configured to dispense the tiles in layers according to the one or more installation parameters; and the tile setting device, arranged according to the suction cup configuration, is configured to grip the tiles, layer by layer, and deposit the tiles to a mounting surface.

Description

Docket No. STS25302PCTMETHODS AND SYSTEMS FOR PATTERN ORIENTED TILE INSTALLATIONCROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Non-Provisional Application No.19 / 088,696, entitled ' METHODS AND SYSTEMS FOR PATTERN ORIENTED TILE INSTALLATION’’, and filed on March 24, 2025. The entire contents of the above-listed application / s) are hereby incorporated by reference for all purposes.FIELD

[0002] Embodiments of the subject matter disclosed herein relate to tile positioning, and more particularly to a tile pattern-oriented installation system for tile staging, positioning, and placement.BACKGROUND AND SUMMARY

[0003] Installing tiles, such as kitchen backsplash tiles, shower tiles, floor tiles, wall tiles for an underground subway, and the like, is a strenuous physical labor that requires a high degree of precision to produce quality tiled surfaces. The skilled labor to do this work is expensive and the time spent doing the installation must be controlled for the work to be profitable. Various devices have been envisioned to aid in tile installation.

[0004] An example of a tile setting apparatus can be seen in U.S. Patent No. 4,091,945 to Patterson. A tile setting apparatus is disclosed which includes a tile holder box for both holding and aligning tiles preparatory to installation of the tiles and a tile setter tool which is releasably secured to the tiles in the tile holder box and removes a plurality of the aligned tiles from the tile holder for placement of the tile for installation. When tiles are picked up by the tile setter by the vacuum process, the user of the apparatus lifts the tiles and places the tiles as desired, usually on a vertically extending wall. When the tiles arc in their proper place or orientation on a wall, or more particularly on an adhesive surface on a wall, a thumb release valve is actuated to allow air to flow into the air chamber which thus relieves the vacuum and causes the suction cups to be released from the tiles.

[0005] U.S. Patent No. 11,007,814 to Zhan discloses a tile gripper with a number of suction cups. The invention provides a mosaic tile paving device which includes a series of suckers and a handle. The suckers are installed on a vacuumizing shell, and the suckers and mosaic tile can be fixed together and separated by changing the air volume in the vacuumizing shell. The vacuumizing shell is connected with a handle. Specifically, the suckers are fixed at the bottom of the vacuumizing shell horizontally and vertically. After the suckers are pasted on all small tiles of the mosaic tile, the air of the vacuumizing shell can be discharged manually.

[0006] U.S. Patent No. 4.583.343 to Camp discloses a tile setting kit for uniform placement of ceramic-type tiles, particularly for setting tiles on a vertical surface. The tile setting kit includes a starter rack with uniformly displaced spacers for the first course of tiles; an elongated guide frame havingDocket No. STS25302PCTreplaceable spacer rails with a plurality of uniformly spaced cross teeth arranged in accordance with selected size tile, the frame having further a bubble level for tile course alignment and a support structure with a brace arm and suction attachment that engages the adjacent lower course of set tiles; a spacer unit with suction attachment for support under the adjacent lower course to prevent slippage; and a tile gun with a releasable suction grip for picking up and placing individual tiles.

[0007] U.S. Patent No. 10.384,433 to Rodriguez describes attachment bases that hold an oscillator to the surface of target object through vacuum suction. Some embodiments may use a venturi to generate vacuum suction while others may use a pump. Instead of a venture, other methods and structures of creating a vacuum, including but not limited to a vacuum generator, mechanical pump, or manual pump, are also contemplated to achieve the desired function of holding an oscillator to a target object. Vacuum engagement may be enhanced with the use of an attachment such as a gel or liquid applied to the surface of the target object prior to engagement of the vacuum.

[0008] U.S. Patent No. 4,893,451 to Valente describes a device having the suction cup operatively connected a vacuum generator of standard construction, and a vibrator. The vacuum generator and vibrator are mounted on a base of the enclosure. When the tile is pressed against the adhesive, the vibrator starts to vibrate, producing a corresponding vibration in the entire enclosure, resulting in vibration of the suction cup. This helps to embed the tile into the adhesive.

[0009] U.S. Patent No. 8.267.386 to Schaaf describes a pneumatically actuated area vacuum gripper for gripping, and if necessary, separating workpieces. In particular, the vacuum gripper is used with thin, flexible workpieces, and has a suction chamber, which has a suction wall with perforations, to be placed on the workpiece. An ejector nozzle has a connection and an outlet, the ejection nozzle being connected to the suction chamber via its coimection, and the outlet of the ejector nozzle opening to the outside or into an exhaust air duct, and the suction inlet of the ejector nozzle empties into the suction, whereby the direction of the air stream in the connection coming from the suction chamber corresponds to the direction of the main air conveyance in the ejector nozzle.

[0010] The inventors herein have recognized several drawbacks to the available devices for tile arrangement and placement. In particular, the aforementioned systems are not adaptable to multiple tile patterns. For example, the tile setting apparatus of Patterson described above suction cups in fixed locations, which may render the apparatus less useful or not useful for certain tile patterns, tile sizes, grout joint sizes, and the like.

[0011] Thus, the inventors have developed systems and methods for pattern-oriented tile installation. In particular, a system includes a computing device, a tile setting device, and a tile dispensing system. Both the tile setting device and the tile dispensing system are arranged according to a pattern specific code determined by the computing device based on one or more tile installation parameters. The tile setting device comprises a control module including at least one venturi powered via an air compressor, wherein the at least one venturi creates vacuum pressure, and a turbine vibrator, and an array module comprising a vacuum chamber fed from the at least one venturi of the controlDocket No. STS25302PCTmodule and a plurality of threaded holes configured to receive either a suction cup or a plug. An arrangement of suction cups and plugs of the array module may be determined according to the pattern specific code such that the arrangement of suction cups corresponds to the desired tile installation parameters, which may include tile size and shape, grout joint size, and tile pattern.

[0012] The tile dispensing system comprises one or more of a number of components, including one or more tile staging trays, a pattern matrix base, one or more tile dispensing cartons, and a tile dispensing crate, used either alone or in various combinations. For example, the pattern matrix base may be arranged according to the determined pattern specific code and may be inserted into a tray and tiles may be stacked in a given pattern according to the pattern specific code within the base. As another example, tiles may be packaged into cartons according to the pattern specific code, wherein layers of patterned tile are stacked within the carton. Cartons may optionally be used in combination with a crate, which incorporates a lifting system for maintaining a desired height of tiles during an installation process.

[0013] The systems for the tile setting device herein disclosed may reduce overall manual labor required for tile installation by reducing the amount of lifting and transport of tiles during installation. Further, installation of multiple tiles at once may increase installation quality by reducing lippage, reducing crooked grout lines, and flattening a resultant tiled wall by reducing the number of individual applications.

[0014] Additionally, the systems for the tile setting device herein disclosed may be adaptable to multiple types of tile patterns and styles. For example, a single tile setting device may be reconfigurable into various different arrangements for use with multiple tile patterns. Determining a pattern specific code according to one or more tile installation parameters may allow users to identify a desired tile setting device configuration as well as receive from the manufacturer or assemble themselves a tile dispensing system that is tailored for their specific tile installation parameters. The pattern-oriented tile installation system herein disclosed thus increases the versatility of tile installation devices.

[0015] It should be understood that the brief description above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify' key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present disclosure will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:

[0017] FIG. 1 is a block diagram of an exemplary pattern-oriented tile installation system comprising a computing device, a tile setting device, and a tile dispensing system, according to one or more embodiments of the present disclosure;Docket No. STS25302PCT

[0018] FIG. 2 shows a top view of an exemplary control module of the tile setting device of the pattern-oriented tile installation system of FIG. 1, according to one or more embodiments of the present disclosure;

[0019] FIG. 3 shows a top view of the control module of FIG. 2 including one or more adjustable guides in a retracted position, according to one or more embodiments of the present disclosure;

[0020] FIG. 4 shows a top view of the control module of FIG. 2 including the one or more adjustable guides in an extended position, according to one or more embodiments of the present disclosure;

[0021] FIG. 5 shows a perspective view of an exemplary array module of the tile setting device of FIG. 1, according to one or more embodiments of the present disclosure;

[0022] FIG. 6 shows a perspective view of a portion of the tile setting device of FIG. 1, according to one or more embodiments of the present disclosure;

[0023] FIG. 7 shows a perspective view of an exemplary tile carton of the tile dispensing system of the pattern-oriented tile installation system of FIG. 1, according to one or more embodiments of the present disclosure;

[0024] FIG. 8 shows a side cross-sectional view of an array of tiles positioned within the tile carton of FIG. 7, according to one or more embodiments of the present disclosure;

[0025] FIG. 9 shows a perspective view of a tile dispensing crate of the tile dispensing system of FIG. 1, according to one or more embodiments of the present disclosure;

[0026] FIG. 10 shows a side cross-sectional view of the tile dispensing crate of FIG. 9, according to one or more embodiments of the present disclosure;

[0027] FIG. 11 shows a top view of a first example pattern of staged tiles positioned within the tile dispensing system, according to one or more embodiments of the present disclosure;

[0028] FIG. 12 shows a top view of a second example pattern of staged tiles positioned within the tile dispensing system, according to one or more embodiments of the present disclosure;

[0029] FIG. 13A shows a perspective view of a filled tile staging tray, according to one or more embodiments of the present disclosure;

[0030] FIG. 13B shows a perspective view of a stack of tile staging trays, in accordance with, one or more embodiments of the present disclosure;

[0031] FIG. 14 shows a perspective view of the tile dispensing crate including a first transport system, according to one or more embodiments of the present disclosure;

[0032] FIG. 15 shows another perspective view of the tile dispensing crate including a second system, according to one or more embodiments of the present disclosure;

[0033] FIG. 16 shows a flowchart illustrating a method of operation of the pattern oriented tile installation system, according to one or more embodiments of the present disclosure;Docket No. STS25302PCT

[0034] FIG. 17 shows a flowchart illustrating a method for arranging a tile dispensing system for use with the pattern oriented tile installation system, in accordance with one or more embodiments of the present disclosure;

[0035] FIG. 18 shows an example of a pattern matrix base, in accordance with one or more embodiments of the present disclosure; and

[0036] FIG. 19 shows the pattern matrix base of FIG. 18 including one or more grout spacers, in accordance with one or more embodiments of the present disclosure.DETAILED DESCRIPTION

[0037] The following description relates to various embodiments for a system and methods for pattern oriented tile installation. In one example, the pattern oriented tile installation system may comprise a computing device configured to determine a pattern specific code based on one or more tile installation parameters, a tile setting device, and a tile dispensing system. The tile setting device comprises a control module and an array module. The array module may include a plurality of suction cups, an arrangement of which may be customizable based on the determined pattern specific code. The control module may be configured to control activation and deactivation of suction cups of the array module. The tile dispensing system comprises one or more components such as tile staging trays with customizable pattern matrix bases, tile cartons, and tile crates, which may be used alone or in various combinations. In use, tiles may be arranged within a chosen tile dispensing system based on the determined pattern specific code, the tile setting device may be arranged in a configuration based on the pattern specific code, and the tile setting device may be used by a user to install tiles from the tile dispensing system to a mounting surface in the specific pattern.

[0038] The pattern oriented tile installation system is shown in a block diagram in FIG. 1. An example of the tile setting device is shown in FIGS. 2-6. Various embodiments of the tile dispensing system arc shown in FIGS. 7-15 and 18-19. A method of operation of the pattern oriented tile installation system is shown in FIG. 16 and a method of arranging a tile dispensing system is shown in FIG. 17.

[0039] Turning now to the figures, FIG. 1 shows a block diagram of a pattern oriented tile installation system 100. The pattern oriented tile installation system 100 may comprise a computing device 102, a tile setting device 116 (which may be referred to herein as a tile gripper), and a tile dispensing system 118. The computing device 102 may comprise one or more processors 104 configured to execute instructions stored in non-transitory memory 106. Processor(s) 104 may be single core or multi-core, and the programs executed thereon may be configured for parallel or distributed processing. In some embodiments, the processor(s) 104 may optionally include individual hardware components that are distributed throughout two or more devices, which may be remotely located and / or configured for coordinated processing. In some embodiments, one or more aspects of the processor / s) 104 may be virtualized and executed by remotely -accessible networked computing devices configured in a cloud computing configuration. The computing device 102 further includes non-transitory memoryDocket No. STS25302PCT106. It should be appreciated that the computing device 102 may include additional memory’ devices, including volatile memory, mass storage, local memory’, and so on.

[0040] Memory 106 includes one or more data storage structures, such as optical memory devices, magnetic memory devices, or solid-state memory devices, for storing programs and routines executed by processor(s) 104 to carry out various functionalities disclosed herein. Memory 106 may include any desired type of volatile and / or non-volatile memory such as, for example, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, read-only memory (ROM), etc. Processor(s) 104 may be any suitable processor, processing unit, or microprocessor, for example. Processor(s) 104 may be multi-processor system, and, thus, may include one or more additional processors that are identical or similar to each other and that are communicatively coupled via an interconnection bus. In some examples, memory 106 may include components disposed at tw o or more devices, which may be remotely located and / or configured for coordinated processing. In some embodiments, one or more aspects of memory 106 may include remotely -accessible networked storage devices configured in a cloud computing configuration. The processor(s) 104 and memory 106 may be coupled, for example, via a communications bus.

[0041] Non-transitory memory 106 may comprise a pattern specific code determination system 108. a gripper configuration system 110, and a dispensing arrangement determination system 112. The pattern specific code determination system 108 may be configured to determine, based on one or more tile installation parameters, a code or data number or the like that is specific to the one or more tile installation parameters of a desired installation pattern. In one example, the one or more tile installation parameters may comprise tile parameters like tile size (w idth and length), type, and manufacturer, a tile pattern (e.g., herringbone, stack bond, ashlar, brick, or the like), and a grout joint size. In some examples, the one or more tile installation parameters may be received from a user input device 114 that is communicatively or operatively coupled to the computing device 102. For example, the computing device 102 may be hosted in a cloud computing platform, accessible via the Internet, or the like, and a user input device such as a desktop computer, laptop computer, mobile device like a smart phone, or the like through which a user may input the one or more tile installation parameters to the computing device 102. In some examples, the user input device may select the one or more tile installation parameters from a preset database, such as a database of industry model names and numbers. As will be described further below, the pattern specific code determination system 108 may determine the pattern specific code based on the one or more tile installation parameters via a look-up table, a sequential filtering algorithm, a mathematical algorithm, or the like. For example, the pattern specific code may correspond to the arrangement of tiles in an optimal nested configuration. In some examples, the pattern specific code may also inform the position and size (e.g., width and length) of the grout joints for input into a CNC machine for milling of pattern specific bases and / or milling and positioning one or more retainers (e.g.. in the example using a tile dispensing tray). In some examples, the patternDocket No. STS25302PCTspecific code determination system 108 may generate a CNC vector file for milling of pattern specific bases and / or retainers for a tile dispensing tray.

[0042] The gripper configuration system 110 may be configured to determine, based on the determined pattern specific code, a configuration of suction cups for the tile setting device 116. In some examples, as will be described below, the tile setting device 116 comprises an array module. The array module of the tile setting device 116 may be selected from one or more available array modules based on the pattern specific code by the gripper configuration system 110. For example, each available array module may have a different grid arrangement of suction cups for gripping tiles, such as an 8x4 grid, a 10x6 grid, or other grid size. The gripper configuration system 110 may assign each threaded hole of the grid of the array module to either a suction cup or a plug based on the pattern specific code. For example, threaded holes that would align with space filling inserts may be assigned to a plug (and therefore deactivated from suction action), while threaded holes that would align with a tile may be assigned to a suction cup. The position of the space filling inserts and the tiles may be known based on the pattern specific code and thus the inserts may be specific to the desired tile installation pattern. The gripper configuration system 110 may output instructions and measurement for the configuration of suction cups for the tile setting device 116 based on the determined pattern specific code. In this way, the tile setting device 116 may be customizable for various tile types and patterns, increasing the versatility and adaptability of the system.

[0043] The dispensing arrangement determination system 112 may determine, based on the pattern specific code, an arrangement of tiles that are to be used with the tile dispensing system 118. For example, as will be described herein, the tile dispensing system 118 may comprise one or more components in which tiles may be stacked in layers. The orientation and pattern of the tiles in each layer may be given by the pattern specific code. For example, a first code may correspond to a brick pattern with tiles of a first size and a grout joint of a first size while a second code may correspond to a herringbone pattern with tiles of a second size and a grout joint of a second size.

[0044] The tile dispensing system 118, as will be further described with respect to FIGS. 7-15, may comprise one or more components such as one or more staging trays with or without pattern matrix bases, tile dispensing cartons, and tile dispensing crates. In some examples, the tile dispensing system 118 may be packaged at a manufacturing facility, according to the pattern specific code, and the pattern specific code may be marked on the package (e.g., in a barcode, in a QR code, in a text label, etc.). Thus, when a user receives the package, the pattern specific code may be easily accessible, which may enable a user to easily determine the corresponding suction cup configuration of the array module of the tile setting device 116.

[0045] As a non-limiting use-case scenario, a user with the tile setting device 116 may input one or more installation parameters to a web-hosted code determination system to determine a pattern specific code, may order a tile dispensing system including packages of tiles in one or more of the aforementioned components according to the pattern specific code, and may then receive the tileDocket No. STS25302PCTdispensing system. The tile dispensing system, for example a pattern oriented dispensing carton, may include a label with the pattern specific code. The user may scan the label to launch instructions for a suction cup configuration for the tile setting device 116 that corresponds to the pattern specific code. The user may then assemble the tile setting device 116, including arranging suction cups and / or plugs in the array module according to the suction cup configuration, and may then proceed to install tiles from the pattern oriented dispensing carton to a mounting surface using the specifically configured tile setting device.

[0046] It should be appreciated that the above use-case scenario is merely exemplary and is not meant to establish the only use for the systems herein disclosed. Other arrangements, embodiments, and use-case scenarios are possible, some of which are enumerated herein.

[0047] FIGS. 2-6 show an example of the tile setting device 116 of the pattern oriented tile installation system 100 of FIG. 1. An axis system 299 is provided in FIGS. 1-5, as well as FIGS. 7-15, for reference. An x-axis may be a lateral axis, a y-axis may be a longitudinal axis, and a z-axis may be a vertical axis (parallel with a gravitational axis). It should be understood that the axes herein provided are for reference and the tile setting device 116 may be moved throughout three-dimensional space in practice. The tile setting device 116 comprises a control module 202 and an array module 502. The control module 202 is shown in FIGS. 2-4 and an example of the array module 502 is shown in FIGS.5-6.

[0048] FIG. 2 shows the tile setting device 116 from a top-down perspective. The tile setting device 116 comprises control module 202. The control module 202 may be configured to provide vacuum suction to suction cups of the array module (e.g., array module 502). The control module 202 comprises a first planar panel 204. In some examples, the first planar panel 204 may be a flat piece of clear polycarbonate. The first planar panel 204 may comprise a clear material so as to allow a user to visualize placement of gripped tiles with respect to a mounting surface, which may increase installation quality.

[0049] A handle array 206, at least one venturi 224, a compressed air connection 226, a compressed air source 228, a compressed air control switch 230, at least one panel connection device 232, and at least one adjustable guide 302 may be coupled to the first planar panel 204. The first planar panel 204 may comprise a first side 290, a second side 292, a first end 294, and a second end 296. The first side 290 may be opposite the second side 292 with respect to tire x-axis and the first end 294 may be opposite the second end 296 with respect to the y-axis. The handle array 206, in one example, may comprise a first handle 208 arranged at the first side 290, a second handle 210 arranged at the first end 294, a third handle 212 arranged at the second side 292, and a fourth handle 214 arranged at the second end 296. The first handle 208 may be coupled to the second handle 210 via a first joining device 216, the second handle 210 may be coupled to the third handle 212 via a second joining device 218, the third handle 212 may be coupled to the fourth handle 214 via a third joining device 220, and the fourth handle 214 may be coupled to the first handle 208 via a fourth joining device 222. Each of the joining devices may comprise perforated joints, wherein the perforations are configured to receive the correspondingDocket No. STS25302PCThandles. The joining devices may be arranged at corners of the first planar panel 204 and may extend perpendicular to the plane of the first planar panel 204 (e.g., along the z-axis). The joining device may be fixedly coupled to an upper surface 240 of the first planar panel 204, for example via an adhesive, one or more fasteners like bolts or screws, or the like. “Upper" in this context is with reference to the z-axis when the tile setting device 116 is positioned parallel with a substantially flat ground surface (e.g., a plane of the first planar surface being parallel with the ground).

[0050] The handle array 206, including the first, second, third, and fourth handles 208, 210, 212, and 214, may be configured for a user to grip and lift the tile setting device 116 with their hands. For example, the handle array 206 may be smooth or ridged cylinders, sized to fit within a hand of the user such that the user may hold onto the handle array 206, for example with a left hand at the first handle 208 and a right hand at the third handle 212, while using the tile setting device 116 to install tiles. In this way, the handle array 206 may comprise a plurality of handle supports (e.g.. the joining devices) and handles extending between the handle supports.

[0051] The first planar panel 204 may comprise an upper surface 240, to which the handle array 206. the at least one venturi 224, the compressed air connection 226, the at least one adjustable guide 302. and the at least one panel connection device 232 are mounted. The first planar panel 204 further comprises a lower surface 236, which is configured to connect to a second planar panel (e.g., second planar panel 504 of the array module 502 described below) via the at least one panel connection device 232. The at least one panel connection device 232 may comprise a quick release locking mechanism, bolts, screws, or other types of fasteners configured to couple the first planar panel 204 to the second planar panel.

[0052] The at least one venturi 224 may be fluidly connected to the compressed air connection 226 and the compressed air source 228. The at least one venturi 224 may create negative pressure using compressed air from the compressed air source 228. The at least one venturi 224 may operate based on the Venturi effect, which defines how fluid (e.g., air) moving through a constricted section of a tube experiences a drop in pressure, thereby creating a vacuum. In operation, compressed air from the compressed air source 228 may be forced through a narrow nozzle within the venturi. As air moves through the constriction, its velocity increases and its pressure drops, thereby creating a vacuum at a side port, which is fluidly coupled to the one or more suction cups via venturi connecting tubes 244.

[0053] As shown in FIGS. 3 and 4, the at least one adjustable guide 302 may be mounted to the upper surface 240 of the first planar panel 204 near an edge 242 of the first planar panel. For example, a first adjustable guide 304 may be arranged at an edge 242 at the first side 290. a second adjustable guide 306 may be arranged at an edge 242 at the first end 294, a third adjustable guide 308 may be arranged at an edge 242 at the second side 292. and a fourth adjustable guide 310 may be arranged at an edge 242 at the second end 296.

[0054] The at least one adjustable guide 302 may be configured to be selectively adjusted between an extended position and a retracted position. For example, when retracted, as shown in FIG. 3. the atDocket No. STS25302PCTleast one adjustable guide 302 may be arranged near the edge 242. Conversely, when extended, as shown in FIG. 4, the at least one adjustable guide 302 may extend outwards from the first planar panel 204. In the example shown in the figures, the first adjustable guide 304 and the third adjustable guide 308 may extend outwards from the first planar panel 204 within the x-y plane along the x-axis and the second adjustable guide 306 and the fourth adjustable guide 310 may extend outwards from the first planar panel 204 within the x-y plane along the y-axis. The adjustable guides may be configured to releasably mate with a portion of the tile dispensing system, for example with an upper edge of a crate or tray thereof. In this way, the adjustable guides 302 may provide a means for consistently and uniformly positioning the tile setting apparatus with respect to the tile dispensing system.

[0055] In some examples, the at least one venturi 224 may comprise two or more venturis 238. In one example, the control module may comprise three venturis 238. Each venturi of the two or more venturis 238 may be provided with a control switch 234 that may be toggled into two or more positions to control operation of the corresponding venturi.

[0056] In some examples, the control module 202 may additionally comprise a vibration system 250. In some examples, the vibration system 250 may be a turbine vibrator. The vibration system 250 may be configured to vibrate the first planar panel 204 and / or connected components, including the array module 502 described below. For example, the vibration system 250 may be coupled to a control switch (not shown). In some examples, the control switch may be an independent control switch for the vibration system 250. For example, the independent control switch may be activated while the tiles are gripped via suction as the tiles are set to the mounting surface. Thus, the control sw itch for the vibration system 250 may be activated after the tiles are released via toggling the control switch 230 that controls the at least one venturi 224 to release the tiles by shutting off the suction. In this way, vibration of the tiles may be performed after the tiles are set at the mounting surface, reducing any movement in the arrangement of the tiles while the tiles are gripped. Vibration of the tile setting device 116 may aid in setting gripped tiles to the mounting surface (c.g., to the tile adhesive that is adhered to the mounting surface).

[0057] In other examples, the control switch 230 may control activation of both the at least one venturi 224 and the vibration system 250. For example, toggling the control switch 230 in a first direction may activate the at least one venturi 224 to provide vacuum suction to the one or more suction cups. Toggling the control switch 230 in a second direction may deactivate the at least one venturi 224 and may activate the vibration system 250 to provide a pulse vibration to the control module, array module, and / or the one or more suction cups.

[0058] FIG. 5 shows the array module 502. In some examples, the array module 502 may include a second planar panel 504, at least one vacuum operated suction cup 514, and at least one mating panel connection device 508. The second planar panel 504 may be one or more flat pieces of clear polycarbonate. In one example, the second planar panel 504 may comprise two pieces of clearDocket No. STS25302PCTpolycarbonate coupled together, for example via adhesive, with one or more components, such as vacuum chambers 516 between the pieces.

[0059] In some examples, the second planar panel 504 may comprise a plurality of holes 520, such as threaded holes. In one example, the plurality of holes 520 may be included in a bottom facing piece of the second planar panel 504. the bottom facing piece being coupled to a top facing piece in order to seal one or more vacuum chambers 516 therebetween. Each of the plurality of holes may be adapted to selectively receive a vacuum operated suction cup or a plug. The vacuum operated suction cup may be configured to connect to one of the one or more vacuum chambers 516. The one or more vacuum chambers 516 may be fluidly coupled to the at least one venturi 224.

[0060] In the example shown, each of the plurality of holes is filled with a suction cup. In other examples, one or more of the plurality of holes may be filled with a suction cup and one or more of the plurality of holes may be filled with a plug. Plugs may be inserted to deactivate the corresponding hole from providing suction via the vacuum chambers. The configuration of plugs and suction cups within the grid of holes of the array module 502 may be defined by a determined pattern specific code. For example, each pattern specific code may correspond to a configuration of suction cups and plugs for a corresponding tile pattern. In this way. the tile setting device 116 may be adaptable for various different tile types and patterns, increasing the versatility of the system.

[0061] As shown in FIG. 5, the at least one suction cup 514 may be mounted to a lower surface of the second planar panel 504. For example, the holes as described above may be of the lower surface of the second planar panel 504. The at least one mating panel coimection device 508 may be mounted to an upper surface 510 of the second planar panel 504. The at least one mating panel connection device 508 may be configured to couple to the at least one panel connection device 232 of the control module 202. For example, the at least one panel connection device 232 may be configured as quick release locking mechanisms that are inserted into the at least one mating panel connection device 508 to bind die control module 202 to the array module 502.

[0062] The at least one suction cup 514 may be fluidly connected to the at least one venturi 224 via venturi connections 518 when the at least one panel connection device 232 is connected to the at least one mating panel connection device 508. For example, each of the venturi connections 518 may be coupled to one of the venturi connecting tubes 244 as well as being in fluid communication with one of the vacuum chambers 516. In particular, the venturi coimections 518 may be configured to fluidly couple the vacuum chambers 516 to the at least one venturi 224 via the venturi connecting tubes 244 when the array module 502 is coupled to the control module 202. In this way. the suction cups may be actuated based on compressed air vacuum in order to adhere to tiles.

[0063] Turning now to FIG. 6. the at least one suction cup 514 of the array module 502 is shown. In some examples, the array module 502 may comprise an array 512 of suction cups 514. The array 512 may be arranged according to a determined suction cup configuration, each of the suction cups 514 in the array 12 may include or otherwise be coupled to a mechanism 602 for attaching the correspondingDocket No. STS25302PCTsuction cup 514 to the array module 502. In some examples, the mechanism 602 may include a screw mechanism that mates with one of the threaded holes of the second planar panel 504. For example, the mechanism 602 may be an offset that attaches to the suction cup and to the corresponding threaded hole.

[0064] As described above, the plurality of holes 520 may be arranged in a grid pattern and the array 512 of suction cups 514 that are activated according to the suction cup configuration may be inserted into the plurality of holes. As described herein, the suction cup configuration may include the arrangement of suction cups of the array module. The grid pattern may be a four-by -eight grid, with four suction cups 514 arranged along a transverse edge of the second planar panel 504 (e.g.. along the first or second side 290. 292) and eight suction cups 514 arranged along a longitudinal edge of the second planar panel 504 (e.g., along the first or second end 294, 296). In other examples, other grid dimensions are possible.

[0065] Each of the suction cups in the array 512 may be a vacuum activated suction device, such as activated via the compressed air control valve. For example, when the array 512 is positioned with one or more of the suction cups 514 in face sharing contact with tiles, for example tiles positioned within the tile staging system, the compressed air control valve may be activated to create a suction to grip the tiles to the suction cups. Then, when the tiles are positioned in a desired arrangement, such as against a mounting surface, the vacuum suction may be released, such as via the compressed air control valve.

[0066] In some examples, as will be further described herein, the one or more suction cups of the array of suction cups 512 that are activated via their corresponding mechanism(s) depending on one or more factors. For example, a determined pattern specific code, which is determined based on a tile pattern, a grout joint size, and tile type, may inform the arrangement of activated suction cups, as herein described. For example, for a herringbone pattern of tiles, a first configuration of suction cups may be utilized for installation of the tiles, while, for a brick pattern of tiles, a second configuration that is different than the first configuration may be utilized.

[0067] It should be understood that while manual activation of suction cups via coupling individual suction cups and individual plugs in a desired arrangement to holes of the array module is herein described, other methods of configuring the array module for specific tile patterns have been envisioned. For example, in another embodiment, the grid of the array module may comprise a grid of fixed suction cups. Each of the fixed suction cups may be individually activated and / or deactivated to achieve a specific arrangement of suction cups, for example by delivery of vacuum to those suction cups designated to be activated and non-delivery of vacuum to those suction cups designated to be deactivated. In yet another example, the suction cups of the array module may each comprises multiple configurations, such as an activated configuration in which the suction cup is extended for gripping of tiles and a deactivated configuration in which the suction cup is retracted within the array module, thereby acting as a plug to the fluid connection to the vacuum chambers 516 for that grid position.Docket No. STS25302PCT

[0068] Turning now to FIGS. 7-15, a tile dispensing system 118 is shown. The tile dispensing system 118 may comprise a tile carton 704, as shown in FIGS. 7-8, a tile dispensing crate 902, as shown in FIGS. 9-12, and a tile staging tray 1300, as shown in FIGS. 13A-B. The tile dispensing system 118, as will be herein described, may be configured to work with the tile setting device 116 described above. For example, tiles assembled in the tile dispensing system 118 may be picked up by the suction cups of the tile setting device 116 for installation. The tile dispensing system 118 may comprise one or more components arranged alone or in combination. For example, in one scenario, the tile dispensing system 118 may comprise tiles arranged on a tile staging tray. In another scenario, the tile dispensing system 118 may comprise tiles arranged within a tile dispensing carton. In yet another scenario, the tile dispensing system 118 may comprise tiles arranged within cartons which are stacked within a tile dispensing crate. These components and various embodiments of the tile dispensing system 118 are further described below. The particular components that are included in the tile dispensing system may be selected based on the installation circumstance. For example, for a small volume installation, the tile staging tray, wherein a user can more easily arrange tiles themselves, may be chosen, while for a high volume installation, the combination of cartons and crates may be used to allow multiple cartons to be installed within the crate for ease during the installation process.

[0069] Referring to FIG. 7. the tile carton 704 is shown. The tile carton 704 may comprise a semirigid box 706 and a semi-rigid lid or top 708. In one example, the box 706 and the top 708 are made of cardboard. The box 706 may comprise four upright (e.g., parallel with the z-axis) walls, and may be open at a top and bottom. In some examples, a pattern specific base or other removable base panel may be coupled to a bottom of the box 706 to act as a bottom of the box 706 onto which tiles may be set.

[0070] The tile carton 704 may additionally comprise the lid or top 708. The top 708 may be configured to fit around the box 706. For example, the top 708 may comprise four sides and a top face. The four sides may be configured for face sharing contact with four of the four upright walls of the box 706, for example the top 708 may be sized to contact the outside surfaces of the walls. In some examples, the lid 708 may be removably affixed to the box 706 via a coupling device 710. In one example, the coupling device 710 is a piece of tape that is wrapped around an edge of the lid 708 when positioned covering the box 706. The coupling device 710 may comprise a removing device, such as a string embedded within the piece of tape that when pulled, severs the tape, thereby allowing the lid 708 to be removed from the box 706.

[0071] The box 706 may be sized and shaped to hold layers of tiles 702. The box 706 may be size and shaped to match with the tile setting device 116. For example, the adjustable guides of the tile setting device 116 may be configured to releasably couple with upper edges of the four walls of the box 706, thereby ensuring proper alignment of the tile setting device 116 with at least one edge of the carton. Further, the box 706 may be sized to match the tile setting device 116 such that the tiles layered within the carton 704 are grippable by the suction cups of the tile setting device 116. In this way. the tile setting device 116 may lift one full layer of tiles from the carton 704 at a time.Docket No. STS25302PCT

[0072] In some examples, the tile cartons may be used in a stand-alone maimer with the tile setting device 116. In other examples, the tile cartons may be used in conjunction with the tile dispensing crate 902, for example for higher volume installations, as shown in FIG. 10. Thus, the tile carton 704 may be configured to fit within the tile dispensing crate 902. For example, the width, length, and height of the tile carton 704 may be configured to nest within the tile dispensing crate 902. Thus, during manufacturing, tile cartons may be formed by placing tiles into tile cartons, per a given pattern specific code that informs tile type, tile pattern, and grout joint size, as will be further described herein. As such, during installation, a single tile crate may be used with multiple, exchangeable tile cartons 704, thus overall reducing the amount of manufacturing and increasing installation efficiency.

[0073] FIG. 8 shows the tile carton 704 from a cross-sectional view. In the cross-sectional view as shown in FIG. 8, the tile carton 704 includes the layers of tiles 702 that are stacked within the carton. The cross-sectional view additionally shows a base 802 of the box 706. In some examples, the base 802 may be a bottom of the box 706, wherein the base 802 is formed of the same cardboard material as the box. In such an example, tiles may be arranged according to a desired pattern without the use of dedicated guides or grout spacers. In some examples, the tiles that are arranged within the carton may comprise nubs on each side that, when set touching (nub to nub), create a grout line. These tiles can simply be loaded in the carton touching each other rather than demanded spacers to maintain the grout joint. In other examples, the base 802 may be a pattern specific base or other removable panel configured to accommodate spacers that act as pattern guides for arranged tiles.

[0074] In examples in which the base 802 is pattern specific, the base 802 may comprise a plurality of manufactured slots through which grout spacers may be placed. The grout spacers may extend vertically, with respect to the z-axis, within the carton, thereby allowing the layers of tiles 702 to be arranged according to the designated tile pattern, tile size, and grout joint size. The grout spacers and slots may be determined according to a determined pattern specific code defined by these parameters, in some examples. In some examples, the cartons may be packaged by a manufacturer and shipped as arranged in the desired arrangement. In other examples, the tiles may be arranged according to the desired pattern orientation at an installation site.

[0075] In examples in which the tile carton 704 is arranged within the tile dispensing crate 902, as described below, the top 708 may be removed prior to positioning the carton within the crate. When one or more cartons are used in conjunction with a tile dispensing crate, the cartons may be stacked on top of each other within the crate, as shown in FIG. 10.

[0076] FIG. 9 shows the tile dispensing crate 902 of the tile dispensing system 118. The tile dispensing crate 902 comprises four walls 904, one of which is shown in FIG. 10. The tile dispensing crate 902 further comprises an open top 906 and a bottom 908. The bottom 908 of the tile dispensing crate 902 may include an opening 910.

[0077] The opening 910 may be configured (e.g., in size and shape) to receive a lifting system 1002, as shown in FIG. 10. The lifting system 1002 may comprise a hydraulic lift, a scissor jack liftingDocket No. STS25302PCTplatform, a spring actuated lifting platform, or other type of lift device. For example, the lifting system 1002 may be weight actuated, hydraulically actuated, or the like. The lifting system 1002 may be configured to lift the plurality of layered tiles 702 to a desired height within the tile dispensing crate 902. For example, the tiles may be desired to be just below a vertical top of the four walls 904. As tile are removed from the crate by the tile setting device 116 layer by layer, the lifting sy stem 1002 may raise the remaining tiles within the crate such that a top layer of the remaining tiles is at the desired height by exerting force on the removable panel 912, which may reduce an installation time and a required manual effort associated with the tile installation. For example, the lifting system 1002 may raise the remaining cartons or tile layers reactively (e.g., based on weight) or in response to user activation (e.g., via a pedal). The desired height may be an ergonomic height and may be set by the user based on the user’s height and the position of the mounting surface.

[0078] In some examples, the tile dispensing crate 902 may comprise a removable base panel 912. The removable base panel 912 is configured to rest on top of (e.g., in face sharing contact with a top face of) the bottom 908. For example, the removable base panel 912 may have dimensions that are slightly smaller than the inner dimensions of the four walls 904 so as to slide within the four walls 904 to rest on the bottom 908. The removable base panel 912 may have dimensions that are larger than the opening 910 such that as the lifting system pushes up against the removable base panel 912. all the remaining layers of tile are lifted.

[0079] In some examples, cartons 704 may be stacked on top of the removable base panel 912, each including a respective base 802. For example, a bottom most carton 704 may be arranged within the positioning crate 902 upon an upper surface 914 of the removable base panel 912, with other cartons 704 stacked upon the bottom most carton. In some examples, additional removable panels may be arranged between cartons for added support and stability .

[0080] In other examples, tiles 702 may be arranged within the tile dispensing crate 902 without the use of cartons. For example, one or more sets of stacked tile layers may be arranged atop of the removable base panel 912. Each of the sets of stacked tile layers may comprise a plurality' of tile layers, such as eight tile layers. Each of the sets of stacked tile layers may be separated by a removable panel. In some examples, the removable panels may be milled to include a plurality of slots that are configured to receive grout spacers, similar to as described with respect below.

[0081] The tile dispensing crate 902 may be configured to hold approximately 100 square feet of tile, as a non-limiting example. For example, each tile dispensing carton may be configured to hold 15-20 square feet of tile (e.g., 8 layers of tile, each layer encompassing 2 square feet), and six cartons may be stacked on top of each other within the carton.

[0082] FIGS. 11 and 12 show top down views of tiles 702 arranged within the tile carton 704, which, in some examples may be positioned within the tile dispensing crate 902. The tiles may be arranged within the tile carton 704 in a desired pattern of a plurality of patterns. For example, as shown in FIG. 11, the tiles 702 may be arranged in a first pattern. For example, the first pattern may be a brickDocket No. STS25302PCTpattern. As another example, as shown in FIG. 12, the tiles 702 may be arranged in a second pattern. For example, the second pattern may be a herringbone pattern.

[0083] When the tiles 702 are positioned within the carton 704, one or more removable inserts 1102 may also be positioned within the carton 704. For example, the one or more removable inserts 1102 may be configured to fit into spaces 1104 of the carton 704. The size and shape of the removable inserts 1102 may depend on the size of the tiles 702 in the tile dispensing carton, the grout joint size, and the tile pattern and arrangement. For example, the first pattern of tiles 702 may comprise tiles 702 of a first size arranged in a brick pattern (e.g., in rows with alternating center alignments). The brick pattern may leave one or more open spaces 1104 that are smaller than the first size of the tiles 702. The one or more removable inserts 1102 may be positioned within the carton 704 to file these open spaces 1104 to maintain the positions of the tiles 702 in the first pattern. For instance, for the first pattern as shown in FIG. 10, four removable inserts 1102 may be arranged around the tiles, wherein the removable inserts are approximately half the size of one of the tiles 702. Each of the removable inserts may be of equivalent size and shape.

[0084] Further, one or more grout spacers 1106 may be arranged between the tiles 702. For example, a removable panel on which layers of tile 702 are positioned may comprise a plurality of milled slots corresponding to grout joints of the pattern specific code, which indicates tile pattern and grout joint thickness. The tiles 702, when arranged within the carton 704, may be positioned in regions between the grout spacers 1106. The grout spacers 1106 may fill the desired grout joint space such that when the layer of tiles is gripped by the tile setting device and lifted out of the carton, the grout joint remains and retains its specified thickness.

[0085] Similarly, for the second pattern of tiles 702, as shown in FIG. 12, the tiles 702 may be arranged at an angle for a herringbone pattern. Thus, when positioned within the carton 704 according to the tile installation parameters, one or more open spaces 1104 may remain, for example in the shape of triangles. The one or more removable inserts may be configured to fit within these triangular spaces 1104 to maintain the positions of the tiles 702 in the herringbone pattern. The size of the triangular inserts may vary for the second pattern, according to the size and arrangement of the tiles 702.

[0086] Turning now to FIGS. 13 A and 13B, the tile dispensing system, when comprising one or more tile staging trays is shown. An exemplary tile staging tray 1300 is shown in FIG. 13A. A stack 1350 of tile staging trays 1300 is shown in FIG. 13B. In some examples, the tile staging trays, for example in a stack, may be used alone, without use of the tile dispensing carton or the tile dispensing crate. For example, when used as a stand-alone, tiles that are shipped to an installation site, not in a desired pattern, may be arranged in the desired tile pattern within a corresponding tile staging tray.

[0087] In the example shown in FIG. 13A, the exemplary filled tile staging tray 1300 is shown. For example, the filled tile staging tray 1300 as shown includes a stack of tiles 702 arranged in a grid pattern (e.g., square tiles arranged in a standard grid). Each tile staging tray 1300 may be adapted to hold around 16 square feet of tile, as a non- limiting example, with approximately 2 square feet of tileDocket No. STS25302PCTper layer of tile and a total of 8 tile layers. Trays may be stacked, as shown in FIB. 13B to increase the volume of tiles available for installation, wherein a user can stack a number of trays corresponding to die amount of tile demanded to cover the mounting surface.

[0088] The tile staging tray 1300 may comprise a fixed base 1308 and a frame 1310. The fixed base 1308 may be configured as a bottom of the tile staging tray 1300, w ith the frame 1310 acting as side walls for the fixed base 1308. The tile staging tray 1300 may comprise the fixed base 1308, an open top, and the frame 1310, wherein the frame 1310 comprises a first side wall 1312, a second side wall 1314, a front wall 1302, and a back wall 1304. The first side wall 1312, the second side wall 1314, the front wall 1302, and the back wall 1304 may extend vertically above the fixed base 1308 to a first predetermined height 1306. The first predetermined height 1306 may be configured to accommodate at least one layer of tiles 702, the array module 502, and at least a bottom edge (not shown) of the first planar panel 204 of the control module 202.

[0089] In some examples, the tile staging tray 1300 may additionally comprise a removable pattern specific base, such as is shown in FIG. 18. Turning briefly to FIG. 18, a removable pattern specific base 1800 is shown, as may be used in combination with the tile staging tray 1300. For example, the removable pattern specific base 1800 may be milled to include a plurality of slots 1802. The plurality of slots 1802 may define a tile pattern, whereby spaces 1804 betw een the plurality of slots 1802 may correspond to an intended position of a tile. The plurality of slots 1802 may correspond to grout joints between tiles. In this way, the slots may be configmed for insertion of grout spacers 1902, as shown in FIG. 19. For example, a grout spacer 1902 may be inserted into a corresponding slot 1802, the grout spacer 1902 extending vertically away from the removable pattern specific base 1800. Thus, when tiles are stacked in layers on the removable pattern specific base 1800, the grout spacers 1902 may define die grout joints for each of the tile layers that are stacked vertically in the tray and the tiles may be held firmly in place by the spacers. In some examples, the grout spacers 1902 may be horseshoe-shaped spacers inserted through the slots 1802 of the removable pattern specific base 1800 prior to placing the removable pattern specific base in the tile staging tray 1300 such that the grout spacers 1902 are fixed in place. In some examples, the tray may be configured to hold 8 layers of tiles. The removable pattern specific base 1800 is shown in FIG. 19 in combination with a tile staging tray 1300.

[0090] Returning to FIGS. 13A-B, the removable pattern specific base 1800. once configured for tile layering (e.g., via milling of slots and placement of grout spacers) may be positioned on top of (e.g., in face-sharing contact with) the fixed base 1308. Tiles may then be placed in available tile spaces within the tile staging tray 1300, on top of the removable pattern specific base 1800. The tile staging tray 1300 in some examples may also be configured to hold corresponding one or more removable inserts 1104. As described above, the removable inserts 1104 may be sized and shaped to fill open spaces between the tile and the frame 1310 that are created based on the tile pattern. In this way, the one or more removable inserts 1104 may maintain the relative positions of the tiles and the grout spacers.Docket No. STS25302PCT

[0091] In some examples, the tile staging tray 1300 may have the same outer dimensions, but may nevertheless be adaptable for holding and dispensing tile in different tile configurations due the one or more retainers as described above. In other examples, tile staging trays 1300 corresponding to different tile patterns may have different dimensions, for example depending on the size and shape of the tile held within the tile staging tray. In some examples, the tile staging tray 1300 may comprise one or more retainers 1316 that are arranged within the frame 1310 to define a dimension of the filled tiles. For example, the tiles 702 that are arranged within the tile staging tray 1300 may not entirely fill a width or length of the tile staging tray 1300. The one or more retainers 1316 may be positioned to define the region of the tile staging tray 1300 that is filled with tiles. For example, the one or more retainers 1316 may be positioned at edges of the removable pattern specific base 1800, which defines the area for tiles.

[0092] The one or more retainers 1316 may comprise one or more of a length retainer and a width retainer. The length retainer may be positioned parallel to the first and second side walls 1312. 1314 and the width retainer may be positioned parallel to the front and back walls 1302, 1304. Which of the length retainer and the width retainer are used and their positioning relative to the tile staging tray 1300 may depend on the dimension of the region of the tile staging tray 1300 that is filled with tiles. In this way, a tile staging tray 1300 may be adaptable for various tile configurations while having the same outer dimensions and utilizing the same frame 1310.

[0093] In some examples, the tiles that are arranged within the tray may comprise nubs on each side that, when set touching (nub to nub), create a grout line. These tiles can simply be loaded in the tray touching each other rather than demanded spacers to maintain the grout joint. In such examples, the pattern matrix base may not be milled and instead may be a substantially flat planar surface on which the tiles rest (e.g., a tray bottom).

[0094] The tile staging tray 1300 may be configured to stack on top of other tile staging trays, as shown in FIG. 13B. For example, a bottom face of the tile staging tray 1300 may comprise a lip that is configured to rest within an inner dimension of the frame 1310 of another tile staging tray 1300 such that a first tile staging tray may be positioned atop a second tile staging tray in a nesting manner, allowing for neat and stable stacking of trays. In this way, multiple tile staging trays may be arranged at an installation site and layers of tile may be removed from a top most tray. When emptied, the top most tray may be removed from the stack, the second highest tray becoming the top most tray of the stack.

[0095] Turning now to FIGS. 14 and 15, the tile dispensing system 118 is shown according to an example. In the example shown in FIG. 14, the tile dispensing system 118 comprises a high lift pallet jack 1402 that is configured to raise a vertical height of the crate 902 and / or of a stack of arranged tile staging trays 1300.

[0096] As a non-limiting example, in an installation scenario, the tile dispensing crate 902 may be moved to the installation site and then raised to a desired height, for example based on a height of the user or a height of the mounting surface, via the high lift pallet jack 1402. In the example shown in FIG.Docket No. STS25302PCT15, the tile dispensing system 118 comprises a manual hydraulic lift cart 1502. The manual hydraulic lift cart 1502 may be adapted to position the crate 902 at a working height for tile installation. In some examples, either the high lift pallet jack 1402 or the manual hydraulic lift cart 1502 may be utilized in combination with the lifting system 1002, wherein the high lift pallet jack 1402 and / or the manual hydraulic lift cart 1502 raises tire crate or carton to a desired installation height and the lifting system 1002 raises the cartons within the crate, thereby increasing the ergonomic nature of the dispensing system. In some examples, the lifting system 1002 may be incorporated as part of a manual hydraulic lift cart 1502 or a high lift pallet jack 1402.

[0097] The tile dispensing crate 902 may be fitted with one or more stacked tile cartons that are each filled with layers of tiles in a given pattern. The tiles within the one or more stacked tile cartons may be installed to a mounting site with the tile setting device 116. For example, suction cups of the tile setting device 116 may be actuated to grip tiles, layer by layer, in order to allow the tiles to be lifted from the corresponding carton, and then deposited to the mounting site by releasing the suction cups. For example, as a top most carton, which is positioned at a desired height, is emptied of tiles using the tile setting device, that top most carton may be removed from the crate. The remaining cartons within the crate may be lifted by the lifting system 1002 to the desired height and the tiles within a next top most carton may be emptied for installation. In some examples, once the one or more tile dispensing cartons are all emptied from the crate, if needed depending on the volume of tiles demanded for the mounting surface, one or more additional cartons may be positioned within the crate and the installation process may be repeated.

[0098] In this way, a single tile dispensing crate 902 may be provided for an installation process, while multiple cartons of tiles are assembled during manufacturing and can be inserted into the single crate as needed during an installation process. This may reduce the overall manufacturing complexity’ by reducing the number of crates that are manufactured.

[0099] Turning to FIG. 16, a flowchart illustrating a method 1600 for pattem-oriented tile installation with a tile installation sy stem is shown. As described herein, the tile installation system may comprise a computing device, a tile setting device comprising a plurality of suction cups, and a tile dispensing system. The method 1600 may be executed at least in part by the computing device, such as computing device 102 based on instruction stored in memory (e.g., memory 106) executable by one or more processors (e.g., processor(s) 104). In some examples, one or more of the steps of the method 1600 may be executed manually by a user of the tile installation system.

[0100] At 1602, method 1600 includes determining one or more tile installation parameters. As an example, the computing device may be communicatively coupled to a user input device through which a user may input the one or more tile installation parameters. The one or more tile installation parameters may comprise a tile type (e.g., size, manufacturer, shape, etc.), a tile pattern (e.g., brick pattern, herringbone, stack bond, ashlar, etc.), and grout joint parameters (e.g.. thickness). In one example.Docket No. STS25302PCTinputting the tile ty pe may include selecting from a preset database of industry’ model names and numbers.

[0101] In some examples, a surface area available for each layer of tile to be arranged in a tile dispensing system may be predetermined, for example when the dimensions of the tile dispensing system are fixed. In other examples, the surface area of tile for each layer may also be included as one of the tile installation parameters. The surface area available may indicate how many tiles are included in a layer and the configuration of those tiles for the given tile pattern, tile type / size, and grout joint thickness. The surface area available may also indicate the sizes and shapes of removable inserts that are to be placed to fill open spaces between the tile and the tile dispensing system.

[0102] At 1604, method 1600 includes determining a tile pattern specific code based on the one or more installation parameters. The tile pattern specific code may be an identification number, alphanumeric code, or the like that is specific to the one or more tile installation parameters. In one example, determining the tile pattern specific code may comprise using a look up table, whereby combinations of tile parameters correspond to a pattern specific code in a table. In another example, determining the tile pattern specific code may comprise using a sequential filtering algorithm. For example, a bank of available codes, each of which is associated with a particular set of parameters, is sequentially narrowed based on each inputted parameter. For example, a set of all available codes may be narrowed to a first subset of codes of that all correspond to a first tile type, the first subset may be narrowed to a second, smaller subset of codes that all correspond to the first tile type and a first tile pattern, and the second subset of codes is narrowed to a single pattern specific code that corresponds to the first tile type, the first tile pattern, and a first grout joint thickness. In yet another example, the pattern specific code may be determined based on one or more mathematical algorithms.

[0103] In some examples, a combination of the above methods for determining the pattern specific code may be utilized. For example, for tile that has been catalogued, inputting the tile ty pe and size, tile pattern, and grout joint size may be correlated to a corresponding code (c.g., via a look up table or filtering method). For tile that has not been catalogued, an exact tile size, desired pattern, and desired grout joint size may be inputted and one or more mathematical algorithms may be executed to define and assign a pattern specific code.

[0104] At 1606, method 1600 includes determining a suction cup configuration for the tile setting device based on the tile pattern specific code. Each tile pattern specific code may be associated with a given suction cup configuration. For example, the memory of the computing device may store a plurality of suction cup configurations that are each associated with a pattern specific code. Upon determination of the pattern specific code, the corresponding suction cup configuration may be detennined.

[0105] As a non-limiting example, the suction cup configuration may be determined based on a number of factors. For example, the tile size and / or total layer dimension may inform the number of suction cups demanded to lift a layer of tile. The tile dimensions and pattern may also inform the positioning of the cups on the tile. For example, cups may be positioned at least a quarter of an inchDocket No. STS25302PCTfrom any edge of a tile, which may indicate the positions of the suction cups and plugs in the array. Additionally, the suction cups may be positioned for balanced weight distribution among the suction cups such that any one suction cup is not holding significantly more weight of tile than another suction cup.

[0106] The pattern specific code, once determined and the tiles are arranged in a given tile dispensing system, may be marked upon the tile dispensing system in any reasonable fashion (e.g., on a printed label, embedded in a QR code or barcode printed upon or stuck upon an outer surface of the tile dispensing system) or otherwise marked upon the packaged shipment of tiles in instances in which the tiles are arranged within the tile dispensing system at the installation site (e.g., using the tile dispensing tray). In this way, the user of the tile installation system may be able to more easily determine, for example by scamiing a barcode, the installation parameters and corresponding determined suction cup configuration that is indicated for the installation parameters.

[0107] As described with respect to FIG. 5, the tile setting device comprises an array module. In some examples, the array module may be selected from a set of available array modules based on the tile pattern specific code. For example, different array modules may comprise different grids that are adapted for different suction cup configurations. The suction cup configuration may comprise an arrangement of suction cups of the array module. In one example, the array module may comprise a grid of holes configured to receive either a suction cup or a plug. The suction cup configuration may inform the positions of one or more suction cups and positions of one or more plugs. The suction cups may be activated to provide vacuum suction for gripping tiles, while the plugs may deactivate the particular grid position such that no suction is provided in that grid position. For example, suction cups may be activated to correspond with the tile positions for the tile pattern and plugs may be positioned to correspond to non-tile positions, such as grout joint positions and removable insert positions (e.g., for the removable inserts 1102).

[0108] At 1608, method 1600 includes arranging the tile setting device according to the suction cup configuration. As described with respect to FIG. 5, arranging the tile setting device may include manually inserting suction cups and plugs into the array module based on the suction cup configuration. For example, the array module may comprise a plurality of threaded holes each configured to receive a suction cup or a plug. The suction cups may be fluidly coupled to one or more vacuum chambers, which are fluidly coupled to one or more venturi connections that couple to one or more venturi of the control module. Thus, the one or more venturis are configured to provide vacuum suction to the suction cups such that the tile gripper may grip a tile via suction. The plugs may deactivate the corresponding grid position from providing vacuum suction. In this way, the array module may be configured to grip tiles arranged according to the one or more tile installation parameters.

[0109] At 1610, method 1600 includes installing tiles, from an arranged tile dispensing system, to a mounting surface. The tile dispensing system may be arranged according to the one or more installation parameters and / or pattern specific code, including milling of slots, placement of groutDocket No. STS25302PCTspacers, and stacking layers of tiles for a pattern matrix base of a tile staging tray and / or milling of slots, placement of grout spacers, and stacking layers of tiles for removable base panels and / or other removable panels for a tile dispensing carton, as will be further described with respect to FIG. 17. Installing tiles may comprise, for each tile layer in the carton, gripping the tiles of the tile layer with the tile setting device, as noted at 1612. For example, the tile setting device may be activated to provide vacuum suction through one or more suction cups. The vacuum suction may thus grip the tiles in the tile layer. Then, for each tile layer, installing the tiles may comprise releasing the gripped tiles at the mounting surface, as noted at 1614. In some examples, releasing the gripped tiles may comprise releasing the vacuum suction, for example via a control switch (e.g., control switch 230).

[0110] In some examples, during release of the vacuum suction for the tile layer, the tile setting device may be vibrated via a vibration system (e.g., vibration system 250), as noted at 1616. Vibration of the tile setting device may provide additional setting into the mounting surface (e.g., into the tile adhesive that is adhered to the mounting surface). Tile installation may be performed in this manner for each tile layer in the tile dispensing system. As is described above, the tile dispensing system may comprise one or more components such as a tile staging tray, a tile dispensing carton, and a tile dispensing crate, either as stand-alone components or in combination.[OlH] FIG. 17 shows a flowchart illustrating a method 1700 for arranging the tile dispensing system according to the one or more tile installation parameters and / or the pattern specific code. In some examples, one or more of the steps of the method 1 00 may be executed manually by a user of the tile installation system.

[0112] At 1702, method 1700 includes determining one or more tile installation parameters. As an example, the computing device may be communicatively coupled to a user input device through which a user may input the one or more tile installation parameters. The one or more tile installation parameters may comprise a tile type (e.g., size, manufacturer, shape, etc.), a tile pattern (e.g., brick pattern, herringbone, stack bond, ashlar, etc.), and grout joint parameters (e.g., thickness).

[0113] At 1704, method 1700 includes determining a tile pattern specific code based on the one or more installation parameters. The tile pattern specific code may be an identification number, alphanumeric code, or the like that is specific to the one or more tile installation parameters. In one example, determining the tile pattern specific code may comprise using a look up table, a sequential filtering algorithm, one or more mathematical algorithms, or the like, as described above.

[0114] At 1706. method 1700 includes arranging the tiles according to the tile pattern specific code within the tile dispensing system. The tile dispensing system may include one or more selected components including a tile staging tray, a tile dispensing carton, and / or a tile dispensing crate, for example based on the installation scenario. As an example, the tile dispensing system may comprise a tile staging tray alone, a tile dispensing carton alone, a tile dispensing crate alone, or one or more tile dispensing cartons used together with a tile dispensing crate (e.g.. with a stack of cartons positioned within a crate). Arrangement of tiles for each scenario is described separately below.Docket No. STS25302PCT

[0115] When the tile dispensing system comprises the tile staging tray used alone, a pattern matrix base may be arranged according to the tile installation parameters, as noted at 1708. The pattern matrix base may be milled to include a plurality of slots that correspond to grout joints of the tile pattern. Grout joint spacers may be inserted into the slots to define the grout joints for the tile pattern and areas for tiles to be positioned. Tiles may then be stacked in layers within the tile staging tray, as noted at 1710. For example, tiles may be positioned between the positioned grout spacers, which define the pattern and tile positions. Each layer of tile may include the same number of tiles in the same pattern orientation. In some examples, removable inserts may be positioned in open spaces and / or one or more retainers may be positioned according to the total dimension of each tile layer as well. The tile staging tray may be utilized as the tile dispensing system in examples in which the tiles are arranged in the desired pattern at the installation site rather than at the manufacturing site. For example, ordered tiles may be shipped to an installation site in a commercial package, and then assembled into the tile dispensing system (e.g., the tile staging tray (s)) by the user prior to installation with the tile setting device.

[0116] When the tile dispensing system comprises one or more tile dispensing cartons, for each set of tile layers (e.g.. sets of 8 layers), a base panel may be configured according to the tile installation parameters, as at 1708. For example, each of the one or more tile dispensing cartons may comprise a base panel upon which a set of stacked tile layers is to be arranged. In some examples, each of these base panels may be manufactured (e g., via milling) to include a plurality of slots that correspond to grout joints. Grout joint spacers may then be inserted into the plurality of slots to define the positions for tiles and the grout joints. The positions and sizes of the slots may correspond to the one or more tile installation parameters, including tile size, tile type, grout joint thickness, and tile pattern. In other examples, the base panel may be a flat planar panel that is not milled and the tiles may be arranged in the desired pattern without the use of grout spacers. Each set of layers may then be stacked within the tile dispensing carton, as noted at 1710. Thus, each tile dispensing carton may be filled with a tile stack, wherein the tile stack comprises a plurality of lay ers of tiles arranged on top of each other in a stack, wherein the bottom layer is arranged on top of a corresponding base panel. The sets of tile stacks may be arranged according to the tile pattern. When the base panels are milled with slots and the cartons comprise grout spacers, the grout spacers separate the tiles to correspond to the desired grout joints.

[0117] When the tile dispensing carton(s) is / are used in conjunction with the tile dispensing crate, a filled carton may be arranged within the crate, as noted at 1712. As noted, the tile dispensing carton may be sized and shaped to fit within the crate. The crate may comprise a bottom with an opening that is configured to receive a lifting system. A removable panel may sit upon the bottom and may be configured to be contacted by the lifting system to lift the carton and / or the tiles within the carton to a desired height during installation.

[0118] In some examples, the tile dispensing crate may be utilized alone without the cartons. In such examples, sets of stacked layers of tiles may be arranged on top of corresponding panels. In some examples, the corresponding panels may be milled to include a plurality of slots that are configured toDocket No. STS25302PCTreceive grout spacers. The sets of stacked layers of tiles, with the corresponding panels, may then be stacked on top of one another and arranged within the crate, atop the removable panel that rests upon the bottom of the crate.

[0119] The tile dispensing carton and / or the tile dispensing crate may be utilized in scenarios in which the tiles are arranged according to the corresponding tile pattern-specific code during manufacture. Thus, cartons that are filled with one or more sets of layered tile stacks may be shipped to an installation site already in the desired configuration.

[0120] In one example, the pattern matrix base, the removable base panel, and / or the removable panels may be inserts that are milled by a milling machine. In some examples, the milling machine that mills the slots in the bases and / or inserted panels may be programmable to automatically mill the slots according to the tile pattern specific code. For example, a user may insert the tile pattern specific code and in response the machine may mill slots that correspond to the one or more tile installation parameters (e.g.. tile size and pattern, grout position and thickness, etc.).

[0121] In any configuration of the tile dispensing system, the tile setting device may be configured to work with the tile dispensing system. For example, the tile staging tray and / or tile dispensing carton and / or tile dispensing crate may be sized to match a size and shape of the tile setting device such that all the tiles in a given layer of tiles may be gripped by the tile setting device when the tile setting device is configured according to the suction cup configuration that is determined based on the same tile pattern specific code for which the tiles were arranged within the dispensing system.

[0122] In this way, the tile installation system as herein disclosed may be configured to adapt to various different tile patterns and arrangements. For example, the system may determine from installation parameters, a pattern specific code that is then used for arrangement of the tile dispensing system as well as a configuration of suction cups of the tile setting device. The tile installation system may thus be more versatile, providing a method for tile installation whereby multiple tiles can be gripped and installed at a mounting site at once that is specific to the desired tile pattern. The tile dispensing system herein disclosed may be a modular system, wherein different components may be selected and used based on a given circumstance. For example, cartons may be packed and repeatedly arranged within a positioning crate during a high-volume installation. During a smaller volume installation, tiles may be arranged within the more compact tile staging tray. The tile dispensing system may be arranged, as described above, according to the one or more installation parameters. For example, tiles may be arranged in a given pattern with grout spacers in place such that during installation, the tile setting device may grip multiple tiles at once with the tiles in a desired arrangement.

[0123] In a practical setting, determining a pattern specific code according to one or more tile installation parameters may allow users to identify a desired tile setting device configuration as well as receive from the manufacturer or assemble themselves a tile dispensing system that is tailored for their specific tile installation parameters. The pattern-oriented tile installation system herein disclosed thus increases the versatility of tile installation devices.Docket No. STS25302PCT

[0124] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising,” “including,” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. The terms “including” and “in which” are used as the plain-language equivalents of the respective terms “comprising” and “wherein.” Moreover, the terms “first.” “second.” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements or a particular positional order on their objects.

[0125] This written description uses examples to disclose the invention, including the best mode, and also to enable a person of ordinary skill in the relevant art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. Docket No. STS25302PCTCLAIMS1. A tile installation system, comprising:a tile setting device, comprising:an array module comprising one or more suction cups; anda control module coupled to the array module, wherein the control module is configured to provide vacuum activation to the one or more suction cups;a tile dispensing system comprising a plurality of tiles stacked in layers: and a computing device comprising a processing unit and memory storing instructions executable by the processing unit to:determine one or more installation parameters:determine, based on the one or more installation parameters, a pattern specific code; anddetermine, based on the pattern specific code, a suction cup configuration for the tile setting device, wherein:the tile dispensing system is configured to dispense the tiles in layers according to the one or more installation parameters; andthe tile setting device, arranged according to the suction cup configuration, is configured to grip the tiles, layer by layer, and deposit the tiles to a mounting surface.

2. The tile installation system of claim 1, wherein the control module comprises at least one venturi fluidly coupled to a compressed air source.

3. The tile installation system of claim 2, wherein the one or more suction cups are in fluid communication with the at least one venturi when the array module is coupled to the control module.

4. The tile installation system of claim 1, wherein the tile dispensing system comprises one or more of a tile staging tray, a tile dispensing carton, and a tile dispensing crate.

5. The tile installation system of claim 1, wherein the tile dispensing system comprises a lifting system configured to reactively raise a height of the tiles as tiles are installed.

6. The tile installation system of claim 1, wherein the tile dispensing system comprises at least one removable panel including one or more slots positioned based on the one or more installation parameters and one or more grout spacers arranged within the one or more slots.Docket No. STS25302PCT7. The tile installation system of claim 1, wherein the one or more installation parameters comprise one or more of tile type, tile pattern, and grout joint thickness.

8. The tile installation system of claim 1. wherein the suction cup configuration comprises an arrangement of tire one or more suction cups and one or more plugs of the array module.

9. The tile installation system of claim 8, wherein the array module comprises a second planar panel comprising a plurality of holes each configured to selectively receive a suction cup or a plug.

10. A method, comprising:determining one or more tile installation parameters;determining a tile pattern specific code based on the one or more tile installation parameters;determining a suction cup configuration based on the tile pattern specific code; arranging a tile setting device of a tile installation system according to the suction cup configuration;installing tiles, from a tile dispensing system of the tile installation system arranged according to the one or more tile installation parameters, to a mounting surface using the tile setting device, wherein the tile setting device comprises a control module coupled to an array module, wherein the array module comprises an array of suction cups arranged based on the suction cup configuration and wherein the control module is configured to provide vacuum suction to the array of suction cups of the array module.

11. The method of claim 10, wherein the control module comprises at least one venturi configured to create vacuum suction for the array of suction cups.

12. The method of claim 11, wherein installing tiles from the arranged tile dispensing system to the mounting surface using the tile setting device comprises:for each tile layer arranged within the tile dispensing system, activating the at least one venturi to grip tiles of the tile layer; andfor each tile layer, deactivating the at least one venturi to deposit the gripped tiles of the tile layer at the mounting surface.

13. The method of claim 12, wherein the control module further comprises a vibration system and wherein installing tiles from the arranged tile dispensing system to the mounting surface using the tile setting device further comprises, for each tile layer, activating the vibration system as tiles are deposited at the mounting surface.Docket No. STS25302PCT14. The method of claim 10, wherein the tile dispensing system comprises a tile staging tray, wherein:the tile staging tray comprises a pattern matrix base comprising one or more slots and one or more grout spacers arranged within the one or more slots, wherein the one or more slots are arranged according to the tile pattern specific code: andone or more layers of tiles are arranged within the tile staging tray on top of the pattern matrix base.

15. The method of claim 10, wherein the tile dispensing system comprises one or more tile dispensing cartons, a tile dispensing crate, and a lifting system, wherein:each of the one or more tile dispensing cartons comprises a box and, wherein one or more layers of tiles are arranged within the box according to the one or more tile installation parameters;the one or more tile dispensing cartons are configured to fit within the tile dispensing crate in a stack; andthe lifting system is configured to raise a height of one or more of the one or more tile dispensing cartons as tiles are installed.

16. The method of claim 1 , wherein the tile dispensing crate comprises an opening in a bottom thereof, wherein the opening is configured to receive the lifting system and the lifting system is arranged within the opening in the bottom.

17. A tile dispensing system, comprising:a tile dispensing crate comprising:a bottom with an opening configured to receive a lifting system;four side walls coupled to the bottom; anda removable base panel configured to sit upon the bottom within the four side walls, wherein the removable base panel is larger in size than the opening of the bottom; andone or more tile dispensing cartons arranged in a stack configured to sit within the tile dispensing crate, wherein each tile dispensing carton comprises a box with an open top, wherein:a set of stacked tile layers is arranged within each of the one or more tile dispensing cartons according to the one or more tile installation parameters; andthe one or more tile installation parameters comprise one or more of tile size, tile type, tile pattern, and grout joint thickness.Docket No. STS25302PCT18. The tile dispensing system of claim 17, further comprising one or more removable inserts configured to fill open spaces the set of stacked tile layers and a corresponding box of a tile dispensing carton.

19. The tile dispensing system of claim 17, wherein the lifting system is configured to raise a height of one or more of the one or more tile dispensing cartons as layers of tiles are removed from the one or more tile dispensing cartons during installation.

20. The tile dispensing system of claim 17, wherein the tile dispensing system is configured to work with a tile setting device that comprises:a control module comprising:a first planar panel.at least one venturi coupled to the first planar panel;a compressed air source fluidly coupled to the at least one venturi;at least one venturi connecting tubes fluidly coupled to the at least one venturi; a handle array coupled to the first planar panel;at least one adjustable guide coupled to the first planar panel; anda control switch coupled to the first planar panel and configured to control activation of the at least one venturi; andan array module selectively coupled to the control module, the array module comprising: a second planar panel coupled to the first planar panel via one or more panel connectors; a grid of holes each configured to selectively receive one of a suction cup and a plug; at least one vacuum chamber fluidly coupled to the grid of holes; andat least one venturi connections fluidly coupled to the at least one vacuum chamber and selectively coupled to the at least one venturi connecting tubes when the array module is coupled to the control module.

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