INTERCONNECTED MODULAR FRAMES FOR PATTERNED GROUTLESS SETTING OF HARD TILES

Abstract

Interlocking modular tile frames may be used to lay and fix tile patterns without requiring a substrate adhesive (thin-set mortar) or grout. Tile frames may comprise integrated segments joined by mechanical interconnection components or a whole. A tile frame forms a rigid or semi-rigid enclosure to hold at least one hard tile within its interior. Each segment has an upside-down T-shape cross-section comprising a column and base. The columns, which frame the held tile, eliminate the need for grout. The inserted tile rests on the base of each segment while being held in place by a column along each edge. One or more mechanical interconnections are located at the base of each enclosure to couple adjacent frames together. Stain-resistant materials 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.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation in part of U.S. patent application Ser. No. 17/750,281, filed on May 20, 2022, and entitled “Interconnected Modular Frames For Groutless Setting of Hard Tiles,” which claims priority to U.S. Provisional Patent Application No. 63/193,749, filed on May 27, 2021, and entitled “Polymer Composite Grout Tile Assembly System,” the entire disclosures of which are incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to tile setting systems.

2. Description of Related Art

Ceramic, stoneware, porcelain, and other hard tiles for floors, walls, countertops, and other surfaces require a suitable adhesive for bonding to a substrate and grout for filling crevices, especially the gaps between tiles. Grout is typically made from cementitious elements that are, by nature, a very porous material that, over time, inevitably becomes stained and discolored from weather, cleaning solutions, food and beverage spills, and normal wear and tear. Chemical sealers temporarily impregnate and seal grouting materials for stain proofing or partial resistance. The best chemical sealers throughout the years have proven to be partially and temporarily effective, at best. Another common disadvantage of standard grout systems is eventual cracking and delamination from the tiling system.

A perfectly tiled surface takes time, expertise, and patience. Tile spacers achieve a consistent pattern before setting tiles and ensure that all tiles are laid equidistant from each other. However, tiles may move after the spacers are removed, and grout still has to be applied to fill the gaps between tiles. Grouting over spacers compromises the structural integrity of the grout joint. Tile laying racks are metal frames that permit the consistent patterning of multiple tiles without spacers. The racks are equipped with one or more handles that allow an installer to remove a rack before setting the tiles with grout.

Interlocking tiles include puzzle edges to join individual tiles to one another. To create a snug, tight fit, the puzzle edges require an interference fit, also referred to as a press fit or friction fit, with a degree of force to mate two tiles. Accordingly, interlocking tiles are suitable for carpets and other soft or flexible materials. Interlocking tile designs are not ideal for hard tiles as puzzle edges are easily damaged, susceptible to breaking during mating, and cannot be manufactured with sufficient precision to form a transition fit without play or movement in the joint.

SUMMARY OF THE INVENTION

The present invention overcomes these and other deficiencies of the prior art by introducing interlocking modular tile frames for joining hard tiles without requiring the substrate adhesive (thin-set mortar) or grout for the laying of repeating tile patterns. In a preferred embodiment of the invention, a frame comprises multiple integrated segments of varying, pattern-specific design that form a rigid or semi-rigid enclosure to hold one or more hard tiles within interior spaces created between the integrated segments. Each segment has an upside-down T-shape cross-section comprising a column and a base. The columns, which form frames to enclose the tiles, eliminate the need for grout. Inserted tiles rest on the bases of one or more segments while being held in place by the columns of each segment. One or more mechanical interconnections are located at outer portions of the enclosure portions of each segment, allowing segments to couple with adjacent segments together to form frames. Further, one or more mechanical interconnections are located at portions of the segments external to the enclosed frame, allowing frames to couple with adjacent frames to form a tile pattern across a surface. 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. Multiple tile patterns can be achieved using this system by adjusting the location of mechanical interconnection points and segment design.

In an embodiment of the invention for laying a half-offset tile pattern, an interlocking modular tile frame comprises a first segment, a second segment, a third segment, and a fourth segment; wherein the segments each comprise a column and a base; wherein the column of each segment is perpendicular to its base, forming a T-shape cross-section; wherein the first and fourth segment comprise “L” shapes with two perpendicular straight segments; wherein the second and third segments comprise a length; wherein the columns and the bases on the first, second, third, and fourth segments are configured to frame a portion of a tile. There are a first, second, third, fourth, fifth, and sixth mechanical interconnection component disposed on the base of the first segment, wherein the first mechanical interconnection component is disposed at the end of one leg of the “L”, the second mechanical interconnection component is disposed at the corner of the “L,” the third mechanical interconnection component is disposed at approximately one quarter of the length of one leg of the “L” on the side opposing the direction in which the other leg extends, the fourth interconnection is disposed at approximately half the length of the same leg of the “L” on the same side that the other leg extends in, the fifth mechanical interconnection component is disposed at approximately three quarters of the length of the same leg of the “L” facing the same side as the third mechanical interconnection component, and the sixth mechanical interconnection component is disposed at the end of the second leg of the “L.” Similarly, there are a seventh, eighth, ninth, tenth, eleventh, and twelfth mechanical interconnection components disposed at the base of the fourth segment wherein the seventh mechanical interconnection component is disposed at the end of one leg of the “L”, the eighth mechanical interconnection component is disposed at the corner of the “L,” the ninth mechanical interconnection component is disposed at approximately one quarter of the length of one leg of the “L” on the side opposite the direction in which the other leg extends, the tenth mechanical interconnection component is disposed at approximately half the length of the same leg of the “L” facing the same direction that the other leg extends in, the eleventh mechanical interconnection component is disposed at approximately three quarters of the length of the same leg of the “L” and on the same side as the ninth mechanical interconnection component, and the twelfth mechanical interconnection component is disposed at the end of the second leg of the “L.” There are a thirteenth and fourteenth mechanical interconnection component disposed on the base of the second segment at each of its ends, and a fifteenth and sixteenth mechanical interconnection component disposed on the base of the third segment at each of its ends. The third mechanical interconnection component, disposed on the first segment, is the counterpart of the thirteenth mechanical interconnection component, disposed on an end of the second segment. The fifth mechanical interconnection component, disposed on the first segment, is the counterpart of the fifteenth mechanical interconnection component, disposed at an end of the third segment. Similarly, the ninth mechanical interconnection component, disposed on the fourth segment, is the counterpart of the sixteenth mechanical interconnection component disposed at the opposing end of the third segment, and the eleventh mechanical interconnection component is the counterpart of the fourteenth mechanical interconnection component disposed at the opposing end of the second segment. When these eight mechanical interconnection components are joined, a tile frame is formed by the first, second, third, and fourth segments, wherein the tile frame is disposed along the lengths of the first and fourth segments, and the perpendicular legs of the first and fourth segments extend in opposite directions away from the frame.

The first and fourth mechanical interconnection components disposed on the first segment are the respective counterparts of the seventh and tenth mechanical interconnection components of the fourth segment. Therefore, a fifth segment identical to the fourth segment can be attached to the first segment on the side opposing the first tile frame, forming a half-offset second tile frame between the perpendicular legs of the first and fifth segments. Similarly, a sixth segment identical to the first segment can be attached to the fourth segment on the side opposing the first tile frame, forming a half-offset third tile frame between the perpendicular legs of the fourth and sixth segments. Tiles in the first tile frame formed by the first, second, third, and fourth unit may be pre-set in formed frame units. The second and third tile frames comprise free unit space in which tiles may be press fit after frames are assembled. Similarly, the second and sixth mechanical interconnection components of the first segment and the eighth and twelfth mechanical interconnection components of the fourth segment are respective counterparts, allowing multiple first segments to be connected end-to-corner and multiple fourth segments to be connected end-to-corner. Connecting first and fourth segments in this manner allows a user to extend the tile frame pattern indefinitely. This connection pattern also requires fewer tiles than frames, as each frame provides support or partial support for multiple tiles.

In one embodiment, the first, second, fourth, twelfth, thirteenth, fourteenth, and fifteenth mechanical interconnection components comprise one or more male protrusions, and the third, fifth, sixth, seventh, eighth, ninth, tenth, and eleventh mechanical interconnection components comprise one or more female indentations. Alternatively, the mechanical interconnection components are genderless. The interlocking modular tile frame may further comprise a mudflap coupled to the base of one or more segments. The mechanical connections between the first and second segments and first and third segments form corners of a quadrilateral first tile frame. The third and fifth mechanical interconnection components are therefore disposed at the corner of the first tile frame. The interlocking modular tile frame may further comprise one or more light sources within the column of one or more of the segments. Alternatively, one or more of the segments comprise a fluorescent material. The height of the columns of the segments is flush with a height of the retained tile. The four sets of counterpart mechanical interconnection components are disposed at corners of the square or rectangular frame or the base extending into an exterior of the frame. This configuration allows a tile to be held within the lengths of the “L” shaped first and fourth segments.

In another embodiment of the invention for laying a hexagonal tile pattern, an interlocking modular tile frame system comprises: two single flange unit segments and two connector unit segments, wherein each flange and connector segment comprises a perpendicular base and column with a T-shaped cross-section, wherein each flange segment comprises a length with three internal corners shaped to fit the edges of a hexagonal tile, wherein each connector segment is a length, wherein the terminal ends of each flange segment comprise a mechanical interconnection component in the direction of the length of the flange segment such that multiple flange segments may be connected end-to-end, wherein each end of each connector segment comprises a mechanical interconnection component, wherein the terminal ends of each flange segment also comprise one half of a mechanical interconnection component such that the combined mechanical interconnection component at the end of joined flange segments corresponds to the mechanical interconnection component at the end of a connector segment, wherein each internal corner of a flange segment also comprises a mechanical interconnection component that corresponds to the mechanical interconnection component at the end of a connector segment. A first flange segment corresponds to a second flange segment such that the internal corners of the first and second flange segments are mirror images of each other. Multiple first flange segments and multiple second flange segments can be joined in parallel, and connectors are used to connect the internal corners and terminal ends of the first and second flange segments. In this manner, two tile frames are formed by a first flange segment, a second flange segment, and three connector segments located at the ends and center internal corners of the flange segments. Additional rows of alternating flange segments may be added to extend the tile frame pattern indefinitely. The height of the columns of the segments is flush with a height of the retained tile.

In another embodiment of the invention for laying a herringbone tile pattern, a segment comprises a “T” shape with two perpendicular legs; the segment comprises a base and column with a T-shaped cross-section; and a first, second, third, fourth, fifth, and sixth mechanical interconnection component are located on the segment. The first mechanical interconnection component is located at the end of one leg of the “T” shape, the second mechanical interconnection component is located approximately one third of the way down the leg of the “T” shape on the side opposite of the perpendicular leg, the perpendicular leg of the “T” shape branches off approximately two thirds of the way down the first leg, the third mechanical interconnection component is located at the end of the “T” shape opposing the first mechanical interconnection component, the fourth mechanical interconnection component is located approximately one third of the way down the perpendicular leg, the fifth mechanical interconnection component is located approximately two thirds of the way down the perpendicular leg on the opposite side, and the sixth mechanical interconnection component is located at the end of the second leg. The first, second and third mechanical interconnection components are male protrusions, and the fourth, fifth, and sixth mechanical interconnection components are female indentations. Alternatively, the mechanical interconnection components may be genderless. Multiple segments are connected by connecting corresponding mechanical interconnection components to form a herringbone pattern, wherein the first mechanical interconnection component corresponds to the fifth mechanical interconnection component, the second mechanical interconnection component corresponds to the sixth mechanical interconnection component, and the third mechanical interconnection component corresponds to the fourth mechanical interconnection component.

Each interlocking modular tile frame may further comprise a mudflap disposed on the base. The present invention is resistant to liquid-based staining and cracking problems, which have been typical throughout the history of the tile industry. Grout is eliminated as the columns along the frames replace it. Tile adhesive is also unnecessary for a floating tile floor. However, some grout may be preferable for securing the frames and tiles to a substrate, particularly when maximum structural integrity is preferred in heavy-weight environments. An underlayment pad may also be used in a floating floor assembly.

The foregoing and other features and advantages of the present invention will be apparent from the following, a more detailed description of the present invention's preferred embodiments and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a complete understanding of the present invention, the objects, and advantages thereof, reference is now made to the ensuing descriptions taken in connection with the accompanying drawings briefly described as follows.

FIG. 1 illustrates a connector segment for a half-offset tile pattern according to an exemplary embodiment of the invention.

FIG. 2 illustrates an upper segment for a half-offset tile pattern according to an exemplary embodiment of the invention.

FIG. 3 illustrates a lower segment for a half-offset tile pattern according to an exemplary embodiment of the invention.

FIG. 4 illustrates a completed frame for a half-offset tile pattern according to an exemplary embodiment of the invention.

FIG. 5 illustrates an expansion of the interconnected modular tile setting system shown in FIG. 4.

FIG. 6 illustrates a single flange unit segment and connector segment for a hexagonal tile pattern according to an exemplary embodiment of the invention.

FIG. 7 illustrates an expansion of the modular tile setting system shown in FIG. 6.

FIG. 8 illustrates a single unit and expansion of a herringbone modular tile setting system according to an exemplary embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Preferred embodiments of the present invention and their advantages may be understood by referring to FIGS. 1-8. The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments to form the described or similar tile patterns. It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from its spirit and scope. Thus, the current invention is intended to cover modifications and variations consistent with the scope of the appended claims and their equivalents. Although the present invention is described in the context of hard tiles such as but not limited to ceramic, porcelain, glass, cement, marble, mosaic, granite, limestone, travertine, quarry, metal, and resin, the interlocking modular tile frames are suitable for any type of tile including soft tiles such as foam, rubber, carpet, cork laminate, and soft plastic, among others.

The present invention comprises connectable repeated-design structures, referred to each individually as a tile frame comprising connected segments. Each tile frame supports at least a portion of one or one or more hard tiles. For example, a quadrilateral tile frame has an exterior flange along each of the sides of its base to support one or more sides of an additional one or more tiles within the tiling system. Therefore, fewer tile frames are required than tiles for a given surface. For example, if one hundred tiles are required for a half-offset pattern project, only twenty tile frames will be required (see FIG. 5 for illustration). As the tile system is assembled, adjacent sides of tile frames create a free space for tile insertion. Various patterns of connected tile frames can be implemented depending on the elected form of the segments. The ratio of tiles to frames will depend on the pattern used. Tiles within the interior of each tile frame may be secured via a press-fit or transition fit. Tiles may be inserted into the tile frames before installation on the floor or other substrates such as a counter or a wall or inserted after the tile frames are connected to the floor or other substrate. Multiple tile frames are connected through interlocking mechanical interconnection components. The frames space and set the tiles in a consistent pattern and are left on the surface after setting, eliminating the need for grout or other gap fillers.

Segments are connected first to form frames, and then to join frames together, by mechanical interconnection components. These mechanical interconnection components may be built in, structural components of the individual sections. Although a limited number of connector types are illustrated (e.g. T-shaped male and female connectors in FIG. 2 at 215 and 225), any size, number, or shaped protrusions and indentations may be used for male and female mechanical interconnection components so long as the corresponding component as described below is similarly shaped, including but not limited to puzzle, tongue, and groove, biscuit, dovetail, and dowell. Alternatively, genderless interconnections, including but not limited to stickle and Lincoln, may be employed. To increase ease of assembly of complex tile patterns, it is possible to manufacture segments such that only corresponding mechanical interconnection components can be joined, utilizing multiple interconnection types on a single segment.

FIG. 1 illustrates a connector segment (100) used to construct a tile frame for a half-offset tile pattern in one embodiment of the invention. This connector segment comprises a column (105) and a base (110), creating a T-shaped cross-section, that extends for a length. The height of the column (105) corresponds to the height of the tile to be contained within the formed frame. The column (105) may be referred to as a “grout column” or “grout strip,” as it takes the place of grout in traditional tile laying systems. The length of the connector segment (100) corresponds to the width of the tile to be contained. The base (110) extends under the tile held within the frame and to the exterior of the frame to support an additional tile on the opposing side. The terminal ends of the connector segment comprise mechanical interconnection components (115 and 120) which correspond to mechanical interconnection components on the upper and lower segments of the frame. The segment may be formed from a rigid or semi-rigid material.

FIG. 2 illustrates an upper segment (200) used to construct a tile frame for a half-offset tile pattern in one embodiment of the invention. This upper segment comprises a column (205) and abase (210), creating a T-shaped cross-section, and further comprises two perpendicular legs of differing lengths. The upper segment also comprises mechanical interconnection components for connection to other segments, including a mechanical interconnection component on the end of the shorter leg (215), a mechanical interconnection component at the corner where the legs meet (220), a mechanical interconnection component located at approximately one quarter of the length of the longer leg (225), a mechanical interconnection component located at approximately half the length of the longer leg (230), a mechanical interconnection component located at approximately three quarters of the length of the longer leg (235), and a mechanical interconnection component at the end of the longer leg (240). The segment may be formed from a rigid or semi-rigid material.

FIG. 3 illustrates a lower segment (300) used to construct a tile frame for a half-offset tile pattern in one embodiment of the invention. This lower segment comprises a column (310) and a base (305), creating a T-shaped cross-section, and further comprises two perpendicular legs of differing lengths. The lower segment also comprises mechanical interconnection components for connection to other segments, including a mechanical interconnection component at the end of the shorter leg (315), a mechanical interconnection component at the corner where the legs meet (320), a mechanical interconnection component located at approximately one quarter of the length of the longer leg (325), a mechanical interconnection component located at approximately half the length of the longer leg (330), a mechanical interconnection component at approximately three quarters of the length of the longer leg (335), and a mechanical interconnection component at the end of the longer leg (340). The segment may be formed from a rigid or semi-rigid material.

FIG. 4 illustrates an assembled tile frame for a half-offset tile pattern according to an embodiment of the invention. The half-offset tile frame (400) comprises four segments: two connector segments (100), an upper segment (200), and a lower segment (300). The segments are connected at four mechanical interconnection points (410, 415, 420, and 425). It can be seen from the illustration that these mechanical interconnection points (410, 415, 420, and 425) comprise a joining of corresponding mechanical interconnection components depicted in FIGS. 1-3. For example, mechanical interconnection point 410, which comprises a corner of the tile frame, is the mechanical joining of mechanical interconnection components 115 from FIGS. 1 and 225 from FIG. 2. A tile may be pre-set into the unit in the appropriate space (405) during frame assembly. It is further illustrated that multiple half-offset tile frames (400) can be joined together to continue the tile pattern across a floor or the desired area. For example, a second tile frame (400) could be attached to either side of this tile frame by mechanically connecting mechanical interconnection component 315 to mechanical interconnection component 230 and mechanical interconnection component 330 to mechanical interconnection component 215. This would result in the attachment of a second completed tile frame, with a tile pre-set in space 405, as well as the creation of a third tile frame with corners at mechanical interconnection components 215 and 230 where a third tile may be press fit after assembly, also referred to as a free unit space (see FIG. 5). Similarly, a second tile frame (400) could be attached to this tile frame by connecting mechanical interconnection component 240 to mechanical interconnection component 220, and mechanical interconnection component 320 to mechanical interconnection component 340. This would result in the attachment of a second completed tile frame, with a tile pre-set in space 405, as well as the creation of a third tile frame with corners at mechanical interconnection points 415 and 425, in line with the two 405 spaces. Such repeating combinations of frames allow a user to extend the tile pattern in any direction indefinitely. It is also apparent that, depending on connections, a single tile frame may support more than one tile.

FIG. 5 illustrates an interconnected modular tile setting system (500) creating a half-offset tile pattern according to an embodiment of the invention. It can be seen from the system that each frame directly connects to four other frames. When five frames are connected, the central frame holds one preset tile and provides half of a frame for four other tiles, the remainder of which are fully enclosed by one of the directly attached frames. When additional frames are attached, such as in the illustrated system (500), a central frame fully encloses one tile, supports four other tiles on two sides, and supports two adinol tiles on one side only. Here, a tile frame (505) comprises an upper segment (510) (with ends at locations M3 and F4) and a lower segment (515) (with ends at locations M1 and F2) combined via two connector segments (520), as shown. It may be noted that each tile frame (505) is depicted in greater detail in FIG. 4 as the tile frame (400). All segments 510, 515, and 520 comprise a column, a base, and optional mud flaps, as disclosed above. As discussed above, any size, number, or shaped interconnections may be used including genderless interconnections; however, gendered connections are discussed for the ease of exemplifying connectivity. The respective connectors are located at M1-M4 and F1-F4. The connector at M1 connects to its counterpart connector at F1, the connector at M2 connects to its counterpart connector at F2, the connector at M3 connects to its counterpart connector at F3, and the connector at M4 connects to its counterpart connector at F4.

Tiles are inserted into the interior of the frames (505), denoted by cross-hatching. Adjacent rows (501 and 502) of tile frames (505) are assembled to form a repeating pattern. When the end of the desired tiled area or an obstacle such as a wall is reached, the lower legs at M1 of the terminal row (see bottom row 501) are cut off and may be saved for other purposes, such as connection to the terminal row at the other end of the tiling space. This row 501 may be set flush to a wall with the upper legs F4, pointing in the direction of the continuing tile pattern, to be connected to the second row (502) of assembled tile frames. The upper legs F4 on the first row (501) attach to the lower body portion of the next upper row (502) (F4 to M4). As this process is continued, an entire row of free space areas (denoted by “FS”) is created between rows 501 and 502, as well as additional free space areas at every other point horizontally within each row 501 and 502. This allows fewer tile frames than tiles to be used in creating the half-offset pattern.

In assembling the tiling pattern, multiple frames may be connected first by connecting an upper segment to a lower segment with two connector segments. The assembled frames may then be connected together using the appropriate connection points, such as by pushing frames inward together to interlock the tile frames (505) via interconnections (e.g. F1-M1, F2-M2, F3-M3, F4-M4). Depending on the type of mechanical connections which are structural components of the segments used, frames may be pushed together horizontally or vertically. Tiles may be inserted into the system (500) after tile frames 110A-D are connected and interlocked, or before interlocking of each tile frame, or a combination of both, depending upon the preference of the user.

FIG. 6 illustrates a single flange unit segment (601) and single connector unit segment (602) for use in laying a hexagonal pattern. The construction of these flange and connector segments is identical to that of the half-offset tile pattern segments but for the angled design and placement of mechanical interconnection components, allowing for the creation of a distinct tile pattern. The connector (602) and flange (601) segments comprise a base and column, also referred to as a grout column as discussed above, which form a T-shaped cross-section. Hexagonal tiles are supported by the base of the segments. The flange segment (601) is designed as a length with three internal corners, arranged such that the flange segment may be fitted around two edges of two hexagonal tiles on one side, or two edges of a single hexagonal tile and one edge of two additional hexagonal tiles on the other side. It is noted that a second species of flange segment which is the mirror image of flange segment (601), depicted in FIG. 7, is used to complete the tile frame pattern. Alternatively, a single species of flange segment (601) may be used if offset by half, such that the internal corners of each segment are the mirror image of each other. Each flange segment terminates in a mechanical interconnection unit (605) on one end and a corresponding mechanical interconnection component (610) on the opposing end. This allows flange segments to be connected end-to-end, extending the tile pattern indefinitely. Each internal corner of a flange segment is shaped to fit a hexagonal tile, e.g. 1200 for a regular hexagon. Each end of the flange segment further comprises one half of a mechanical interconnection component (615). Thus, when two flange segments are connected, a complete mechanical interconnection component is formed (620). A complete mechanical interconnection unit (620) is also located at the outside point of each internal corner of the flange segment. These complete mechanical interconnection components (620) correspond to mechanical interconnection components (625) located on either side of the connector segment. This allows multiple rows of flange segments (601) connected by connector segments (625) to form tile frames, as depicted in FIG. 7.

FIG. 7 illustrates an interconnected modular tile setting system (700) utilizing a regular hexagonal pattern according to an embodiment of the invention. Here, a flange segments (701 and 702, which are mirror images of each other) are connected by connector segments (703) to form tile frames. Two flange segments and three connector segments are utilized to form two complete tile frames. When a single additional row of flange segments is added, an additional row of hexagonal tiles may be laid between the row and the existing tile frames. In this way, as depicted, 16 flange segments form frames for 24 tiles and an additional 8 half-tiles.

FIG. 8 illustrates an interconnected modular tile setting system (800) utilizing a rectangular herringbone pattern according to an embodiment of the invention. Here, a tile frame (805) comprises a segment with a first leg (810) and a second perpendicular leg (815) combined at a ninety angle, as shown. Multiple segments (810) are designed to connect at connection locations A, B, C, D, E, and F to form a tile frame. For example, a number of connectors (depicted as two, female or male) are located at each A-F position. However, any size, number, or shaped protrusions and indentations may be used. Alternatively, genderless interconnections may be employed. Connectors located at A connect to their counterpart connectors located at E. Connectors located at B connect to their counterpart connectors located at F. Connectors located at C connect to their counterpart connectors located at D. Connecting two or more segments by these connectors creates an integrated connected pattern of spaces for the insertion of rectangular tiles in what is termed in the industry as a herringbone pattern. In this system (800), the tiles could not be pre-inserted into the segments but would be inserted after the frames were assembled on the substrate. In an exemplary embodiment of the invention, the tile size is 12″×24,″ but any size tile can be utilized. Mudflaps can also be designed into this system (800), as noted above.

The primary design configuration of each tile segment is intended to be as a whole unit with multiple sides manufactured together as a whole or one singular part. It can be noted from the figures described above that segments other than connector segments all include at least one angle, connecting multiple segment legs, to hold tiles in repeating patterns other than simple aligned square rows. Using traditional tile-laying techniques, these patterns would be more difficult to achieve, and require the placement of each tile to be carefully measured to avoid variations in the pattern. However, other configurations are also proposed as a practical means of design. For example, each leg of a segment may be manufactured separately with similar interlocking connection points for repeating patterns with greater variability, or entire frames may be manufactured as single segments (e.g. a single unit comprising an upper segment (200), lower segment (300), and two connector segments (100)) with interlocking connection points for ease of assembly.

Preferably, there is no excess play or movement of the tiles within the tile frames 110. Accordingly, the inner perimeter of the tile frames relative to the outer periphery of the tiles 120 should be sized to permit an interference fit or transition fit. The interior periphery of the tile frame is slightly smaller than the outer periphery of the tile to be set within the frame. This allows a firm snap-in of the tile into the tile frame. Utilizing a semi-rigid composite plastic presents a flush/tight fit between tiles. It is noted that most manufacturers' lines/styles of tiles fluctuate in size to a small degree, e.g., a few thousandths of an inch. This system accounts for such variations. The width of column may vary as desired, for example, between ⅛″ and 1″. The height of column preferably matches the height of the tiles to provide a flush surface. The height of the base may be varied as well; however, ¼%″ or more permits optional thin-set mortar or padding, if desired, to be placed underneath the tiles.

Hard tiles can be permanently bonded to a substrate such as a floor, a countertop, or a wall through cementitious thin-set mortar, the implementation of which is apparent to one of ordinary skill in the art. Thin-set mortar is applied to the substrate before the system 100 is assembled. Alternatively, the mortar is applied to the substrate exposed within the open interiors of the tile frames after they are interlocked and before tiles are inserted. The system can also be installed as a floating floor with little or no thin-set mortar (not applicable for counters or walls). Assembly of a floating system may utilize a padded insert on the substrate within the interior free space of the interlocked tile frames, slightly thicker than the height of the base, before insertion of the tiles. The pads optimize the support of the tiles, emphasizing floor system weight-bearing integrity. For example, each tile frame would have a correspondingly-shaped pad within its interior underneath a respective tile.

The column may be a different material than the base to decrease material cost and therefore manufactured as two separate components. For example, because column is exposed to the environment, including floor traffic if the substrate is a floor, the column should be a wear-resistant and 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. The base must be an appropriate material to bear the weight of the tiles and anything placed on top of the tiles, the identification of which is apparent to one of ordinary skill in the art. If manufactured separately, the column and the base can be joined via a press-fit or other fastening means, the identification and implementation of which is apparent to one of ordinary skill in the art. In an alternative embodiment of the invention, each side of a tile frame, e.g., the segments, can be a separate component, interlocked using the various interconnections described herein.

Optional flaps or mud flaps may be included on the outer parts of the base for free space tiles. Assuming an installer uses thin-set mortar, the flaps will depress the mud away from base, where a tile will be sitting. There must be no foreign contaminates between the tile and the base it sits upon, as the tile and the top of the column must be perfectly flush. The mudflaps are not needed within the interior of the tile frame because an installer may pre-set the tile into the tile frame before installing it on the substrate. Pre-installation of the tiles is not needed with a floating floor or partial adhesion using a caulking gun application adhesive.

In various embodiments of the invention, tile frames may comprise aluminum and other metallic-based materials, silicone-based materials, and rubber-based materials. Pigmentation may be used to enhance specific colors. One or more textures may be included on the top of column for aesthetics or to prevent slipping. The tile frames taught herein can be manufactured utilizing 3D printing, injection molding, casting processes, forged processes, extrusion methods, or stamping/die processes, among others suitable for the materials disclosed, the identification and implementation of which are apparent to one of ordinary skill in the art.

The materials mentioned above and manufacturing processes may be customized to produce various pigmented options for the grout column in this system. The color, texture, and thicknesses of grout columns can be modified to present unique aesthetic appearances that are impossible within conventional cementitious grouting products. Alternating colors among adjacent tiles frames is also possible with this system, considering the advantages of particular manufacturing processes mentioned above, i.e., 3D printing capabilities. For example, various segments or two sides of a tile frame can be designed in one color and the other two sides in another color. This color and texture variation opens new and creative opportunities for innovative designs.

In addition, the present invention provides precise dimensional accuracy during the installation of the tile system. Standard tile setting processes require spacers and installer accuracy. Even with the most skilled and seasoned installer, all projects invariably will have areas that are imperfect angles within tile settings. The present invention is engineered to ensure consistent dimensions and angles throughout the entire project with its interlocking connections.

The column may additionally comprise one or more light sources along its top surface. A plurality of light sources can run along the entire column perimeter of the tile frame. Exemplary light sources include but are not limited to individual light-emitting diodes (LED), LED strips, rope lights, and LED neon lights. Each light source may be flush with the top surface of column or below the top surface. For the latter configuration, the column is preferably transparent or semitransparent. Low voltage electrical wiring in the tile frame, the implementation of which is apparent to one of ordinary skill in the art, couples the light sources to one another, light sources on adjacent tile frames, or to an external power source (not shown). Lighted tile frames offer a unique ambiance and a lighted pathway. In addition, a fluorescent material such as aluminate can be incorporated into a tile frame so that it charges through natural or synthetic light to emit a soft fluorescent glow.

The invention has been described herein using specific embodiments for illustration only. However, it will be readily apparent to one of ordinary skill in the art that the principles of the invention may be embodied in other ways. Therefore, the invention should not be regarded as limited in scope to the specific embodiments and claims.

Claims

1. An interlocking modular tile frame comprising:

a first segment, wherein the first segment comprises a column and a base, wherein the column is perpendicular to the base, wherein the column and base are configured to frame a portion of a tile;

a first mechanical interconnection component disposed at the base of the first segment, wherein the first mechanical interconnection component is positioned within the length of the first segment;

a second mechanical interconnection component disposed at the base of the first segment, wherein the second mechanical interconnection component is positioned at the end of the first segment;

a second segment, wherein the second segment comprises a column and a base, wherein the column is perpendicular to the base, wherein the column and base are configured to frame a portion of a tile;

a third mechanical interconnection component disposed on the base of the second segment, wherein the first mechanical interconnection component is a counterpart of the third mechanical interconnection component;

a fourth mechanical interconnection component disposed on the base of the second segment;

a third segment, wherein the third segment comprises a column and a base, wherein the column is perpendicular to the base, wherein the column and base are configured to frame a portion of a tile;

a fifth mechanical interconnection component disposed on the base of the third segment, wherein the fourth mechanical interconnection component is a counterpart of the fifth mechanical interconnection component;

a sixth mechanical interconnection component disposed at the base of the third segment, wherein the second mechanical interconnection component is a counterpart of the sixth mechanical interconnection component.

2. The interlocking modular tile frame of claim 1, wherein a completed tile frame supports all sides of at least one tile.

3. The interlocking modular tile frame of claim 1, wherein a completed tile frame supports a portion of at least nine partially offset tiles.

4. The interlocking modular tile frame of claim 1, wherein the first segment and the third segment each comprise at least one corner not used to frame the contained tile.

5. The interlocking modular tile frame of claim 1, wherein the first segment and the third segment have additional mechanical interconnection components that can be used to connect tile frames together.

6. The interlocking modular tile frame of claim 1, where the third mechanical interconnection component is located at the end of the second segment.

7. The interlocking modular tile frame of claim 1 further comprising a mudflap coupled to the base of the first segment.

8. The interlocking modular tile frame of claim 1 further comprising one or more light sources within the column of the first segment.

9. The interlocking modular tile frame of claim 1, wherein the first segment comprises a fluorescent material.

10. An interlocking modular tile frame system, comprising:

a first interlocking modular tile frame configured to retain a first tile within its interior, wherein the first interlocking modular tile frame comprises a first segment, a second segment, and a third segment, and a first mechanical interconnection component, a second mechanical interconnection component, a third mechanical interconnection component, a fourth mechanical interconnection component, a fifth mechanical interconnection component, a sixth mechanical interconnection component, a seventh mechanical interconnection component, and an eighth mechanical interconnection component; a second interlocking modular tile frame, third interlocking modular tile frame, and fourth interlocking modular tile frame, wherein each modular tile frame is configured to retain a tile within its interior, wherein each interlocking modular tile frame is identical to the first interlocking modular tile frame, and wherein two mechanical interconnection components on each of the second interlocking modular tile frame, third interlocking modular tile frame, and fourth interlocking modular tile frame are used to connect that interlocking modular tile frame to the first interlocking modular tile frame.

11. The interlocking modular tile frame system of claim 10, wherein the connection of two tile frames creates a free space capable of supporting a tile.

12. The interlocking modular tile frame system of claim 10, wherein adjacent retained tiles and free spaces are offset.

13. An interlocking modular tile frame, comprising:

a tile comprising a flat surface and a plurality of edges;

a first segment, wherein the first segment comprises a vertical column perpendicular to a horizontal base, wherein the height of the column corresponds to the height of the tile, wherein the base extends to either side of the column, wherein one side of the base supports a portion of the tile, wherein the shape of the first segment contains at least one angle;

a first mechanical interconnection component disposed on the base and between the ends of the first segment, wherein the first mechanical interconnection component is disposed at a corner of the tile;

a second mechanical interconnection component disposed on the base of the first segment;

a second segment, wherein the second segment comprises a vertical column perpendicular to a horizontal base, wherein the height of the column corresponds to the height of the tile, wherein the base extends to either side of the column, wherein one side of the base supports a portion of the tile;

a third mechanical interconnection component disposed on the base of the second segment at an end of the second segment, wherein the third mechanical interconnection component corresponds to the first mechanical interconnection component, wherein a joining of the first and third mechanical interconnection component may be used to combine the first segment and the second segment to support and secure a portion of the plurality of edges of the tile;

a fourth mechanical interconnection component disposed on the base of the second segment;

a third segment comprising a vertical column perpendicular to a horizontal base, wherein the height of the column corresponds to the height of the tile, wherein the base extends to either side of the column, wherein one side of the base supports a portion of the tile;

a fifth mechanical interconnection component disposed on the base of the third segment, wherein the fifth mechanical interconnection component corresponds to the fourth mechanical interconnection component, wherein a joining of the fourth mechanical interconnection component and fifth mechanical interconnection component may be used to combine the second segment and the third segment to support and secure a portion of the plurality of edges of the tile;

a sixth mechanical interconnection component disposed on the base of the third segment, wherein the sixth mechanical interconnection component corresponds to the second mechanical interconnection component, wherein a joining of the second mechanical interconnection component and sixth mechanical interconnection component may be used to combine the first and third segments to support and secure the remaining edges of the tile such that the tile is situated along only a portion of the base of the first segment and third segments;

a seventh mechanical interconnection component disposed on the base of the first segment and offset from the first mechanical interconnection component and second mechanical interconnection component;

an eighth mechanical interconnection component disposed on the base of the first segment and offset from the first mechanical interconnection component and second mechanical interconnection component;

a ninth mechanical interconnection component disposed on the base of the third segment and offset from the fifth mechanical interconnection component and sixth mechanical interconnection component, wherein the ninth mechanical interconnection component corresponds to the seventh mechanical interconnection component; and

a tenth mechanical interconnection component disposed on the base of the third segment and offset from the fifth mechanical interconnection component and sixth mechanical interconnection component, wherein the tenth mechanical interconnection component corresponds to the and eighth mechanical interconnection component, wherein identical frames may be combined by a joining of the seventh and ninth mechanical interconnection components and a joining of the eighth and tenth mechanical interconnection components.

14. The interlocking modular tile frame of claim 1, wherein the first segment, the second segment, and the third segment are all of the same form.

15. The interlocking modular tile frame of claim 1, wherein the first segment comprises a flange segment and a connector segment, wherein the flange segment and connector segment are coupled by a counterpart pair of mechanical interconnection components, wherein the connector segment comprises a length with a mechanical interconnection component at each end.

16. The interlocking modular tile frame of claim 15, wherein the flange segment comprises an “L” shape with two perpendicular legs.

17. The interlocking modular tile frame of claim 15, wherein the flange segment comprises a “W” shape with three internal corners.

18. The interlocking modular tile frame of claim 15, wherein the first segment and the flange segment are mirror images of each other.

19. The interlocking modular tile frame system of claim 10, wherein the first tile frame comprises additional mechanical interconnection components and attaches to additional tile frames.

20. The interlocking modular tile frame system of claim 10, wherein connections between tile frames may comprise connector segments joining appropriate mechanical interconnection components.