Groutless Tile Coupling Mechanism for Fast Installation
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Solution Overview
Problem
Existing tile installation methods are labor-intensive and costly due to the need for grouting, which is time-consuming and requires messy grout application, and current DIY solutions either use laminate materials or are not suitable for durable materials like ceramic or stone tiles.
Innovation Solution
A groutless tile system featuring tiles with cooperative coupling members, such as male and female types, that secure adjacent tiles without the need for grout, utilizing durable materials like ceramic or stone and a substrate with extended portions for spacing and locking, allowing for easy installation and eliminating the grouting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tile installation with grout is used, then tiles are securely bound and moisture is reduced between tiles, but installation becomes labor-intensive and time-consuming
Solution Approach 1:
The tile system divides the binding function into two parts: adhesive binds tiles to the substrate, while coupling members on adjacent tiles bind to each other to secure tiles to neighboring tiles. This segmentation eliminates the need for grout and enables faster installation without compromising tile binding security
Solution Approach 2:
Coupling members act as intermediaries between adjacent tiles, providing a mechanical connection that replaces the need for grout. These coupling members engage with each other to securely bind tiles together while allowing for quicker installation compared to traditional grouting methods
2Object-affected harmful factors
If grout is applied to fill spaces between tiles, then moisture barrier is provided, but the process becomes messy and labor-intensive
Solution Approach 1:
The grout application step is completely extracted from the installation process. Instead of applying grout to provide moisture barrier and tile binding, the system uses pre-integrated coupling members that mechanically secure tiles without requiring messy grout application, thereby simplifying the installation process while maintaining moisture protection
Solution Approach 2:
The coupling members are self-contained features molded into the tiles themselves, providing both mechanical binding and moisture barrier functions without requiring external grout material. This self-service approach eliminates the need for separate grout application and cleanup operations
3Ease of operation
If laminate materials are used for DIY tile solutions, then installation becomes easier, but durability is reduced compared to traditional ceramic or stone tiles
Solution Approach 1:
The tile system uses composite construction with a substrate providing structural strength and durability (similar to traditional ceramic or stone tiles), while integrated coupling members provide the ease of installation. This composite approach combines the durability of traditional materials with the installation simplicity of modern DIY products
4Shape
If coupling members extend beyond the durable component, then spacing between tiles is maintained, but the substrate structure becomes more complex
Solution Approach 1:
The coupling members and spacing functions are merged into a single integrated feature. The coupling members extend beyond the durable component to provide both mechanical coupling between tiles and consistent spacing, eliminating the need for separate spacing elements and reducing overall system complexity
Data Source
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AI summary
Method for making a groutless tile comprising: providing a durable component (102); molding a substrate (104) to receive at least a portion of the durable component (102); affixing the durable component (102) to the substrate (104); and milling at least a portion of the substrate (104) to create a first coupling member (220) on an edge of the substrate (104) and a second coupling member (340) on another edge of the substrate (104).