Modular Tile Frames Eliminate Grout and Adhesive

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Solution Overview

Problem

Conventional tile setting systems require grout and adhesive, which are prone to staining, cracking, and delamination, and interlocking tile designs for hard tiles are not suitable due to precision and durability issues.

Innovation Solution

Interlocking modular tile frames with integrated segments and mechanical interconnections that eliminate the need for grout and adhesive, using stain-resistant materials like polyethylene and polyvinyl chloride to create a rigid enclosure for tiles, allowing for a press-fit installation without substrate adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If grout is used to fill gaps between tiles, then the gaps are filled and tiles are secured, but the grout becomes stained and discolored over time

Engineering Contradiction:

Improvegap filling durabilityVSAvoidstaining and discoloration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes grout entirely from the tile installation system. Instead of filling gaps between tiles with grout, the system uses spacers to maintain consistent gaps and allows the gaps to remain open, eliminating the staining and discoloration problems associated with grout while still achieving secure tile installation through the spacer-based framework

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces spacers as intermediary elements that perform the function of maintaining gap consistency and providing structural support without being subject to staining. The spacers act as a mediator between tiles, replacing grout's gap-filling function while avoiding its deterioration issues

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If adhesive is used to bond tiles to substrate, then tiles are securely attached, but the adhesive eventually cracks and delaminates

Engineering Contradiction:

Improvetile attachment strengthVSAvoidadhesive service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent eliminates adhesive from the system entirely. Tiles are installed using a mechanical framework of spacers and support elements that provide structural attachment without relying on adhesive bonds, thereby avoiding the cracking and delamination that plague adhesive-based installations over time

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a mechanical support system consisting of spacers, nubs, and framework elements that physically hold tiles in place. This mechanical approach provides durable attachment without the deterioration issues of adhesive degradation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If tile spacers are used to ensure consistent patterning, then tile alignment is improved, but tiles may move after spacers are removed and grout is still required

Engineering Contradiction:

Improvetile alignment consistencyVSAvoidtile position stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent combines the alignment function and the structural support function into a single integrated spacer system. The spacers not only maintain consistent spacing for alignment but also provide ongoing structural support to prevent tile movement, eliminating the need for separate grout application while maintaining both precision and stability

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If interlocking tiles with puzzle edges are used, then tiles can join without adhesive, but the puzzle edges are easily damaged and cannot form precise fits

Engineering Contradiction:

Improveadhesive-free installationVSAvoidjoint fit precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent uses spacers as intermediary elements that provide the precise geometric relationships needed for tile alignment without requiring precision-machined interlocking edges on the tiles themselves. The spacers maintain consistent gaps and provide structural support, allowing tiles to join without adhesive while achieving precise fits through the mediator's geometric control

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11840847B2Interconnected modular frames for groutless setting of hard tiles

Publication Date: 2023.12.12 PERRINE ROBERT N

AI summary

Interlocking modular tile frames for joining hard tiles without requiring a substrate adhesive (thin-set mortar) or grout. Each tile frame comprises integrated segments that form a rigid or semi-rigid enclosure to hold a single hard tile within its interior. Each segment has an upside-down T-shape cross-section comprising a column and a base. The columns, which frames a tile, eliminate the need for grout. An inserted tile rests on the base while being held in place by the column along each segment. One or more mechanical interconnections are located at an outer portion of each enclosure corner to couple adjacent frames together. A stain-resistant material such as but not limited to polyethylene, polycarbonate, polyvinyl chloride (PVC), polypropylene (PP), acrylic, ABS (acrylonitrile butadiene styrene), nylon, rubber, or a combination thereof, can be used for the frames.