US20250305300A1

US20250305300A1 - Integrated modular frames with factory-affixed tiles for groutless tiling

Info

Publication number: US20250305300A1
Application number: US19/235,408
Authority: US
Inventors: Robert N. PERRINE
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-05-27
Filing date: 2025-06-11
Publication date: 2025-10-02

Abstract

Interlocking modular tile frame units with factory-affixed tiles enable the installation of repeating hard tile patterns without the need for substrate adhesive (thin-set mortar) or grout. Each tile frame unit is precision-engineered to hold a hard tile that is affixed to the frame prior to delivery to the installation site, ensuring exact alignment and minimal joint width. The frame may be constructed from two or more integrated segments. The columns, which form a continuous perimeter around the tile, serve as a resilient grout replacement, eliminating the need for traditional grout. Mechanical connectors, including male and female types, are strategically positioned along the frame's exterior to enable secure end-to-end and side-to-side connection with adjacent units, supporting a variety of tile patterns such as grid and offset configurations. Optional features include cross support bars for added structural reinforcement, mud flaps for thinset mortar applications, and sound dampening pads for acoustic comfort. The grout replacement column is preferably manufactured from thermoplastic polyurethane (TPU) for flexibility and durability, while other frame components are made from stain-resistant plastics such as polyethylene terephthalate (PET) or polypropylene (PP). This system delivers a robust, groutless, and maintenance-friendly solution for modern hard tile installations, offering superior performance, ease of installation, and long-term aesthetic appeal.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patent application Ser. No. 18/217,334, filed on Jun. 30, 2023, and entitled “Interconnected Modular Frames for Patterned Groutless Setting of Hard Tiles,” which 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 the aforementioned applications are incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to groutless tile setting systems.

2. Description of Related Art

Conventional installation methods for ceramic, stoneware, porcelain, and other hard tiles present persistent challenges that underscore the need for an improved system. Traditional tile installations require adhesives to bond tiles to a substrate and grout to fill the joints between tiles. However, grout, which is typically made from cementitious materials, is inherently porous and inevitably becomes stained and discolored over time due to exposure to weather, cleaning agents, spills, and everyday wear. Even the best chemical sealers offer only temporary and partial protection against staining. Moreover, grout joints are prone to cracking and delamination, leading to unsightly and structurally compromised surfaces.
Achieving a flawless tiled surface is labor-intensive and demands considerable expertise. Tile spacers are used to maintain consistent spacing, but tiles can shift after the spacers are removed, and grout must still be applied to fill the gaps. Grouting over spacers weakens the joint, and while tile laying racks can help maintain patterns, they must be removed before grouting, adding complexity to the process. Interlocking tile systems such as those using puzzle edges work well for soft or flexible materials but are unsuitable for hard tiles, as the rigid edges are easily damaged and manufacturing tolerances make a precise, stable fit difficult to achieve.
Poliacek, as disclosed in U.S. Patent Application Pub. No. 2004/0216420 A1, is an example of a prior art interlocking tile frame system that sought to improve upon traditional tile installation by eliminating the need for adhesives and grout. In Poliacek's system, a lattice of railings and railing ties is assembled on-site to form a series of tile receptacles. Each tile is supported around its perimeter by these railings, and a raised border integral with the support structure serves to replace grout, while the tiles are elevated above the substrate to provide a warmer floor and to facilitate easier replacement of damaged tiles. Yet, the on-site assembly of railings and ties is labor-intensive and can result in inconsistent alignment and spacing, especially over large surfaces or when using rectified tiles that require high dimensional precision. The adjustable nature of the railings, while flexible, makes it difficult to achieve the ultra-narrow, seamless joints and perfectly flush surfaces expected in contemporary designs. The rigid border that substitutes for grout may not adequately accommodate minor variations in tile or substrate, potentially leading to visible gaps, movement, or instability over time. Additionally, the system lacks dedicated internal support beneath each tile, increasing the risk of flexing or cracking, particularly problematic in floating floor applications where robust structural reinforcement is essential.
Rectified tiles, which are ceramic or porcelain tiles that have been precisely ground or cut after firing, ensure nearly identical dimensions and perfectly straight edges. This allows for minimal grout joints and a sleek, modern appearance. However, rectified tiles require a perfectly flat substrate and precise installation, making the process more demanding and costly. Despite their advantages, rectified tiles alone do not solve the persistent issues of grout maintenance and installation complexity.
These limitations in current tile installation methods highlight a clear need for a novel approach that eliminates grout-related problems, reduces installation time and skill requirements, avoids inconsistent tile alignment and spacing, and ensures long-term durability and aesthetic appeal.

SUMMARY OF THE INVENTION

The present invention overcomes the limitations of prior art tile installation systems by introducing an advanced interlocking modular frame system specifically engineered for groutless setting of hard tiles. Unlike earlier approaches that required labor-intensive on-site assembly of adjustable rails and ties, which could lead to inconsistent alignment and visible gaps, the present invention features factory-affixed rectified tiles within precision-molded modular frames. Each frame is constructed from two or more snap-together components, tailored to the exact dimensions of the selected tile line, ensuring a seamless, uniform appearance with minimal joint width. In an exemplary embodiment of the invention, the system utilizes a semi-flexible thermoplastic polyurethane (TPU) grout replacement column, which is manufactured separately and snaps into place, accommodating minor tile variations and natural thermal expansion while providing a tight, durable joint. Integrated cross support bars within each frame deliver robust structural reinforcement, particularly for floating floor applications. The modular units are designed for efficient, rapid assembly and can be easily disassembled if needed, significantly reducing installation time and skill requirements. This innovative approach not only eliminates the need for traditional grout and substrate adhesives but also ensures long-term durability, superior aesthetics, and a cleaner, more reliable installation process for a wide range of tile patterns and configurations.
In an embodiment of the invention, the invention is directed to an interlocking modular tile frame system comprising a tile frame unit having four sides, with a plurality of mechanical connectors disposed on the four sides and positioned to enable end-to-end and side-to-side connection of the tile frame unit to an adjacent tile frame unit at each of the four sides, wherein the four sides define an interior space. A tile is factory-affixed to the tile frame unit within the interior space, and a column is factory-affixed to two of the four sides of the tile frame unit. In certain embodiments, the tile frame unit comprises two segments that join together, through mechanical connectors, to form the tile frame unit. Alternatively, the tile frame unit may comprise four segments, each segment forming one side of the tile frame unit with adjacent segments that join together, through mechanical connectors, to form the tile frame unit. The column may comprise two pieces, each of which is factory-affixed to a side by snapping into a dedicated groove. The two pieces are preferably manufactured as grout replacement pieces from thermoplastic polyurethane (TPU). The system may further comprise at least one mud flap disposed on a base of at least one side, the mud flap being configured to divert thinset mortar away from a portion of the plurality of mechanical connectors during installation. The plurality of mechanical connectors comprises male connectors on a first side and a first end of the frame, and female connectors are positioned on a second side and a second end of the frame. The system may further include at least two cross support bars configured to provide structural reinforcement and may also comprise a sound dampening pad positioned within a void on the underside of the tile frame unit.
In another embodiment of the invention, the invention provides an interlocking modular tile frame system comprising a tile frame unit having four sides and a plurality of mechanical connectors disposed on the four sides, the connectors positioned to enable end-to-end and side-to-side connection of the tile frame unit to an adjacent tile frame unit at each of the four sides, wherein the four sides define an interior space configured to receive a tile, and a column is affixed to two of the four sides of the tile frame unit. The tile frame unit may comprise two segments that join together, through mechanical connectors, to form the tile frame unit, or may comprise four segments, each segment forming one side of the tile frame unit with adjacent segments that join together, through mechanical connectors, to form the tile frame unit. The column may comprise two pieces, each of which is factory-affixed to a side by snapping into a dedicated groove, and the two pieces are manufactured as grout replacement pieces from TPU. The plurality of mechanical connectors may comprise male connectors on a first side and a first end of the frame, and female connectors positioned on a second side and a second end of the frame. The system may further include at least two cross support bars configured to provide structural reinforcement.
In yet another embodiment, the invention provides a method for installing a tiled surface, comprising providing a plurality of interlocking modular tile frame units, each frame unit comprising a rigid or semi-rigid enclosure formed of at least two or more segments, each segment having a base and a column, the columns forming a perimeter on two of the segments and around an interior space, and a plurality of mechanical connectors disposed on outer portions of the two or more segments. The method includes factory-affixing a hard tile within the interior space of each interlocking modular tile frame unit, positioning a first row of the interlocking modular frame units along a wall and removing a portion of the plurality of mechanical connectors adjacent to the wall, and installing subsequent rows by aligning the male connectors of each frame unit with the female connectors of an adjacent frame unit and snapping the units together to form a continuous, groutless tiled surface. The method may further comprise inserting cross support bars into the underside of each frame unit for structural reinforcement, inserting a sound dampening pad into the underside of each frame unit, and utilizing mud flaps on the frame units to divert mortar away from the connectors during installation.
The present invention offers a range of significant advantages over both traditional tile installation methods and prior art systems. By eliminating the need for grout and adhesive, the system resolves longstanding issues such as grout staining, cracking, and maintenance, providing a durable, hygienic, and visually seamless surface. The use of factory-affixed rectified tiles ensures precise alignment and minimal joint width, resulting in a sleek, contemporary appearance that enhances modern interior spaces and makes rooms appear more expansive. The modular frames are engineered for rapid, error-free installation, reducing both labor time and the skill required, while also allowing for easy disassembly or replacement of individual units if needed.
The use of semi-flexible TPU grout replacement column accommodates minor tile variations and natural thermal expansion, ensuring tight, consistent joints and long-term performance. Integrated cross support bars within each unit provide robust structural reinforcement, particularly important for floating floor applications, and optional sound-dampening pads further enhance comfort and acoustic performance. The system is also highly versatile, supporting a variety of tile configurations and patterns, and can be manufactured efficiently for high-volume production.
Altogether, these features make the present invention not only easier to maintain since there are no porous grout lines to clean or reseal but also more durable and resistant to moisture, stains, and wear. The result is a reliable, aesthetically superior, and user-friendly solution that addresses the core deficiencies of both conventional grout-based installations and earlier modular systems.
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 top view of a tile frame unit according to an embodiment of the invention.

FIG. 2 depicts the tile frame unit of FIG. 1 in an exploded view, illustrating its principal components prior to assembly.

FIG. 3 illustrates the tile frame unit of FIG. 1 with a factory-affixed tile secured within the modular frame.

FIG. 4 depicts the tile frame unit of FIG. 1 , illustrating its tile placement stops.

FIG. 5 depicts the tile frame unit of FIG. 1 in a detailed view, illustrating the assembly of the grout replacement column into the frame.

FIG. 6 illustrates multiple tile frame units ready for assembly, though shown without tiles for clarity.

FIG. 7 illustrates the multiple tile frame units fully assembled and joined together, though shown without tiles for clarity.

FIG. 8 illustrates the modular tile frame system with tiles factory-affixed within each tile frame unit.

FIG. 9 depicts the tile frame unit of FIG. 1 from the underside, illustrating the integration of an optional sound dampening pad.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Preferred embodiments of the present invention and their advantages may be understood by referring to FIGS. 1-9 . 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.
The invention introduces an advanced system of interconnected modular frames engineered for the groutless installation of hard tiles, such as ceramic and porcelain, in a wide range of patterns and applications. Each tile frame unit is manufactured to the precise dimensions of rectified tiles, ensuring tight, uniform joints and a seamless, modern appearance. The system is composed of modular frames that are either assembled from two snap-together halves or four individual legs, allowing for efficient, high-volume production and easy assembly. Tiles are factory-affixed into each frame unit using construction adhesive, guaranteeing perfect placement, and minimizing on-site labor. The term “factory-affixed,” as used in the context of the present invention, broadly refers to the process by which a component such as a tile, column, or other element is permanently or semi-permanently fastened, joined, or attached to another component (such as a frame unit) during the manufacturing process at the factory, prior to delivery or installation at the project site. This attachment is performed under controlled factory conditions to ensure precision, consistency, and quality. The result is that the affixed component becomes an integral part of the assembly, eliminating the need for the installer to perform this attachment in the field and thereby improving both the reliability and efficiency of the overall installation process.
Factory-affixing tiles ensures precise and consistent alignment within each frame, which is vital for achieving the ultra-narrow, seamless joints and flush surfaces demanded by contemporary groutless tile installations. In contrast, on-site assembly whether by hand or with adjustable frame systems like Poliacek introduces the risk of misalignment due to human error, substrate irregularities, or the flexing of grout replacement materials, often resulting in visible gaps, uneven joints, or compromised aesthetics.
A factory-controlled environment allows for the use of automated precision machinery, which can position and bond tiles with sub-millimeter accuracy, a level of consistency that is extremely difficult to replicate during manual installation. This automation not only guarantees uniformity across every unit but also dramatically increases production efficiency and reduces labor costs, supporting high-volume manufacturing at scale. By eliminating the need for on-site adhesive application and tile placement, the system minimizes installation time and skill requirements, making the process accessible to a broader range of installers and reducing the potential for costly errors or rework.
Prior art systems, such as those described by Poliacek, relied on labor-intensive on-site assembly of railings and ties to create tile receptacles, which led to inconsistent results and failed to address the challenges of precise alignment and robust structural support especially with rectified tiles that require exact tolerances. The present invention's approach of integrating rectified tiles into modular frames at the factory, with dedicated features such as snap-fit grout replacement columns, represents a significant departure from both traditional and earlier modular methods. This innovation ensures that each unit arrives at the installation site fully prepared, with all critical tolerances and alignments already established, thereby overcoming the persistent limitations of prior art, and delivering a superior, maintenance-friendly, and aesthetically advanced groutless tile system.
FIG. 1 illustrates a top view of a tile frame unit 100 according to an embodiment of the invention. Tile frame unit 100 is composed of two main halves 110 and 120 that snap together to form a rigid enclosure for a factory-affixed tile. Each unit 100 includes a perimeter grout replacement column 130 along two sides (e.g., the top and left sides as shown). The column 130 is a separate piece manufactured from semi-flexible thermoplastic polyurethane (TPU) and designed to snap into the assembled frame 100, providing a continuous, resilient joint around the tile and accommodating minor tile size variations and thermal expansion. The main structural body of tile frame unit 100 is made from polyethylene terephthalate (PET), polypropylene, or a similar rigid plastic, ensuring strength and dimensional stability. The term “snap” refers to a snap fit locking the corresponding components together with secure mechanical interlock, the implementation of which is apparent to one of ordinary skill in the art.
The unit 100 is equipped with a series of connectors for assembly: male connectors 140 are positioned on one end and side of the frame (e.g., the top and left sides as shown), designed to insert into corresponding female connectors 150 located on the opposite end and side of adjacent units, enabling secure end-to-end and side-to-side connections. This connector arrangement allows for rapid, tool-free installation and ensures that the assembled tile frame units maintain precise alignment and structural integrity across the tiled surface.
To form the starter row, tile frame units 100 are positioned along the wall, always working from left to right. Before installation, all “C” male connectors 140 are removed from the units that will be placed against the wall, allowing the units to fit flush, and leaving a standard ½-inch expansion gap between the grout replacement column and the wall, in accordance with industry standards. Additionally, on the very first tile frame unit in the left-hand corner, the two “A” male connectors 140 on the left side are also removed to ensure proper spacing at the beginning of the row. This configuration allows the starter row to sit semi-flush against the wall, ready for the rest of the installation to proceed.
In certain embodiments, the end connectors (designated as “A” connectors) are specifically engineered to differ from the side connectors (“C” connectors) in both geometry and function. The A connectors are configured to provide a compression fit when adjoining tile frame units are connected end-to-end, thereby imparting a secure, unified structure across the length of the installed row. This compression fit is not achieved with the “C” connectors, which are optimized for side-to-side connections without imparting the same degree of compressive force. The use of the “A” style connectors at the ends of each row is particularly critical for establishing and maintaining an overall compression fit throughout the tiled array, with heightened importance for the first starter row. The initial compression fit provided by the “A” connectors at the ends of the starter row ensures a stable and properly aligned foundation for the subsequent installation process, thereby enhancing the integrity and uniformity of the entire modular tile system. In other embodiments, the “A” and “C” connectors are the same.
Once the starter row is in place, the installation of the second and subsequent rows follows a straightforward snap-fit process. Each new unit is aligned so that its side-fit “C” male connectors 140 line up with the “D” female connector ports 150 of the units in the previous row. The installer pushes the new unit forward into the cavity and then applies lateral pressure to the left, causing the unit to snap into place via a pressure fit. As this process is repeated, the compression-fit “A” male end connectors 140 of each new unit are inserted into the corresponding “B” female connector ports 150 of the adjacent unit in the same row, locking the units together both side-to-side and end-to-end. This dual-connection method ensures that each tile frame unit is securely anchored in the array, providing a stable, continuous surface.
The male “C” connectors are designed to engage with the corresponding female cavity “D” to achieve a secure and flush connection between adjacent units. While the illustrative embodiment of FIG. 1 depicts eight “C” connectors along the longer side of each unit, it has been determined that only two male “C” connectors, one at each end of the unit, are preferable to ensure a reliable connection during installation. Incorporating more than two connectors along this edge can hinder the assembly process by generating excessive compression, which complicates alignment and engagement.
Accordingly, in an embodiment of the invention, each unit 100 will be produced with only two permanent male “C” connectors positioned at the respective ends of the longer side, as indicated by the “C” labels in the referenced illustration. The remaining “C” connectors may be fabricated as individual, separate components, to be utilized by the installer as required during the installation process.
This configuration addresses a practical installation scenario: as each row of tile frame units is laid out, the row will typically terminate at a wall, necessitating the trimming or cutting of the final unit to fit the available space. For example, using a 24″×12″ tile, the minimum length of an end tile/unit after trimming may range from 6″ to 23.75″. When a unit is cut to a shorter length, it will retain only one of the original male “C” connectors, which is insufficient for a proper and secure connection at both ends of the cut piece. To resolve this, the portion of the unit 100 formerly equipped with eight male “C” connectors will instead feature two permanent male” “C” connectors at the ends and six female “D” cavities distributed between them. These female cavities are engineered to accept the new individual male “C” connectors, which are manufactured as separate snap-in parts.
During installation, when a tile/unit is cut to the required length, the installer can simply insert the individual male “C” connector into the appropriate female cavity at the freshly cut end, thereby restoring the necessary two-connector configuration for a secure and stable fit. This ensures that each end tile/unit, regardless of its trimmed length, will have the requisite two male connectors for proper engagement with adjacent units.
Referring to FIG. 2 , tile frame unit 100 is depicted in an exploded view, illustrating its principal components prior to assembly for use in a groutless tile installation system. The unit comprises two main halves, 110 and 120, which are designed to snap together to form a rigid, rectangular, or square frame that securely holds a hard tile. Each half defines a portion of the frame's perimeter and incorporates a column 130, which, when the two halves are joined, creates a continuous grout replacement column around the tile. This column 130 acts both as a spacer and as a resilient, grout-replacing joint, accommodating minor variations in tile size and allowing for natural thermal expansion.
Additionally, tile frame unit 100 includes two cross support bars 170, which are designed to click into place from the underside of the assembled frame. These cross support bars 170 provide essential structural reinforcement, particularly for floating floor installations, by supporting the weight of the tile and minimizing flexing or movement under load. The modular construction of the unit not only simplifies manufacturing enabling efficient injection molding or extrusion of the individual halves and support bars but also allows for a variety of tile patterns and installation configurations. When fully assembled, the two main halves 110 and 120, the continuous column 130, the interlocking male 140 and female 150 connectors, and the cross support bars 170 together provide a robust, groutless frame that maintains consistent tile spacing, supports the tile structurally, and enables seamless connection to adjacent units for large-scale or patterned installations.
In an alternative embodiment, each tile frame unit 100 is constructed from four separate individual legs rather than two main halves 110 and 120. In this configuration, each leg forms one side of the rectangular or square frame and is engineered to snap together at the corners using integrated mechanical connectors. Referring to FIGS. 1 and 2 , the two-piece, snap-together construction with a four-part assembly process, where the two main halves 110 and 120 are halved at the corners to form four independent segments or legs. The four legs are joined through a snap fit at the corners to form a complete perimeter frame that securely encloses the tile. Each leg includes a portion of the grout replacement column, which, when assembled, forms a continuous semi-flexible joint around the tile, just as in the two-half embodiment. The cross support bars, as shown in previous figures, are still incorporated and click into place from the underside of the assembled frame to provide additional support, particularly for floating floor applications.
This four-leg construction offers several manufacturing and functional advantages. It is particularly well-suited for high-volume production using injection molding, as each leg can be molded individually, reducing material waste, and simplifying the molding process. The modularity of the four-leg approach also allows for greater flexibility in accommodating different tile sizes and patterns, as legs of varying lengths can be combined to create frames for both standard and offset tile layouts. Additionally, this method can facilitate more efficient packaging and shipping, as the frame components can be nested or stacked prior to assembly.
Overall, the alternative four-leg embodiment maintains all the functional benefits of the two-half design such as factory-affixed tiles, integrated grout replacement columns, and cross support bars while offering increased manufacturing efficiency, versatility in pattern configuration, and ease of assembly for installers.
Referring to FIG. 3 , tile frame unit 100 is shown with a factory-affixed tile 300 secured within the modular frame, illustrating the assembled state of the system as used for groutless tile installation. In this configuration, the frame unit 100 includes only two permanent male “C” connectors 140, one positioned at each end of the longer side of the frame. Female connectors 150 (hidden but underneath tile 300) are located on the opposite sides to enable secure interconnection with adjacent units. Cross support bars 170 (hidden but underneath tile 300) are integrated into the underside of frame unit 100 to provide essential structural reinforcement, particularly for floating floor applications.
Again, during installation, when a tile/frame unit 100 must be trimmed to fit at the end of a row such as against a wall the resulting cut unit will typically retain only one of the original male “C” connectors 140. To ensure that each end tile/frame unit maintains the required two male “C” connectors 140 for proper and secure attachment, the system is designed so that the installer can snap an additional individual male “C” connector 140 into a dedicated female cavity 150 provided along the frame at the cut end. This allows every tile/frame unit 100, regardless of its final trimmed length, to be equipped with two male “C” connectors 140 at its ends, thereby preserving the structural integrity and stability of the modular assembly throughout the installation process.
Referring to FIG. 4 , the frame 100 may also include optional tile placement stops 180, which are molded features that ensure the tile 300 is positioned accurately within the unit during factory assembly. These stops 180 serve as mechanical guides that engage with the tile edges after adhesive application, constraining the tile 300 against the interior corner formed by the grout replacement column 130. The semi-flexible TPU material comprising the grout column, while essential for accommodating thermal expansion and tile tolerances, exhibits sufficient compliance to permit minor displacement if unconstrained. Without the rigid alignment provided by stops 180, manual or automated pressing of the tile against the column during adhesive curing could result in misalignment due to localized deformation of the TPU column, compromising joint uniformity across adjacent units. In high-volume manufacturing environments employing automated precision placement systems with computer vision guidance, the need for physical stops 180 may be reduced or eliminated. Advanced machinery can achieve sub-millimeter alignment accuracy through robotic positioning and real-time feedback systems, potentially rendering the mechanical stops redundant for mass production scenarios. However, the stops 180 may be needed for manual assembly processes or manufacturing lines without such precision automation capabilities.
Referring to FIG. 5 , tile frame unit 100 is shown in a detailed view highlighting the assembly of the grout replacement column 130 into the frame. In this embodiment, tile frame unit 100 is designed with a dedicated female groove 610 that runs along the interior perimeter of the frame. During assembly, column 130 is aligned with the female groove 610 and pressed into place, where it snaps securely into the groove due to its flexible properties. This snap-fit connection allows the column 130 to accommodate minor variations in tile size as well as natural thermal expansion, ensuring a consistent and durable joint around each tile. The design of the female groove 610 and the snap-in column 130 not only streamlines the assembly process but also enhances the system's ability to maintain precise joint widths and prevent moisture ingress.
FIG. 6 illustrates multiple tile frame units 100 ready for assembly, illustrating the modular connection system. Tiles 300 have been removed for illustrative purposes. During installation, the male connectors 140 of one tile frame unit 100 are aligned with the corresponding female connectors 150 of the neighboring unit. The installer then presses the units together, allowing the male connectors 140 to snap firmly into the female connectors 150, creating a stable and seamless connection.
FIG. 7 illustrates the multiple tile frame units 100 fully assembled and joined together, though shown without tiles for clarity. Each tile frame unit 100 features a continuous grout replacement column 130 running along its perimeter, which, when the units are connected, forms a seamless and resilient joint between adjacent tiles. The units are equipped with male connectors 140 and female connectors 150, which are strategically positioned along the frame edges to enable secure and precise attachment. The completed assembly demonstrates how the modular system creates a uniform, groutless floor or wall installation, with each unit structurally integrated into the overall array.
FIG. 8 illustrates the modular tile frame system with tiles 300 factory-affixed within each tile frame unit 100. The illustration demonstrates the system installed in a half-offset (½ offset) pattern, with the top row representing the starter row positioned against a wall and subsequent rows continuing the pattern. For the starter row, the male connectors along the top and far left edges are removed to allow the units to fit semi-flush against the wall, leaving a standard expansion gap that will be covered by baseboard after installation. As subsequent rows are installed, the system accommodates partial tiles at the beginning and end of each row to maintain the offset pattern, with the frames and tiles fitting seamlessly together.
When installing the modular tile frame system using thinset mortar, mud flaps 190 play a crucial role in ensuring a clean and secure installation. The mud flaps are integrated into the base of one or more frame segments and are specifically designed to divert thinset mortar away from the adjoining male and female connector pieces and ports. This prevents thinset from contaminating the mechanical connection points, which is essential for achieving a flush and precise fit between adjacent frame units. During installation, thinset mortar is applied to the substrate using a notched trowel, creating an adhesive bed for the tile frame units. As the units are pressed into the mortar, the mud flaps function as barriers, channeling excess thinset away from the connectors and maintaining the integrity of the snap-fit or interlocking system. This ensures that all connected areas remain uncontaminated and that the frames can be properly joined, resulting in a stable, permanent bond to the substrate. The use of mud flaps 190 in conjunction with thinset mortar thus allows the system to combine the advantages of a groutless, modular installation with the strength and durability of a traditional bonded tile floor, making it suitable for environments where maximum structural integrity is required.
Referring to FIG. 9 , a tile frame unit 100 is depicted from the underside, illustrating the integration of an optional sound dampening pad 910 within the modular system. The dampening pad may comprise closed-cell ethylene-vinyl acetate (EV) A foam and is positioned in the voids on the backside of the tile frame unit 100, fitting securely within the frame's structure without interfering with the mechanical assembly or the placement of the tile. This pad is designed to absorb and reduce noise transmission through the floor, e.g., a 25 dB noise reduction, providing enhanced acoustic comfort in residential or commercial environments. The inclusion of a dampening pad is particularly advantageous in floating floor installations, where the absence of adhesive bonding can otherwise allow for increased sound or vibration transfer. By incorporating this feature, the system not only delivers the benefits of groutless, modular tile installation but also addresses the need for improved sound insulation, making it suitable for multi-story buildings, apartments, or any setting where noise reduction is a priority. The dampening pad can be made from high-quality acoustic foam or other advanced damping materials, ensuring durability, moisture resistance, and long-term performance without adding significant bulk or complexity to the installation process.
In an embodiment of the invention, the manufacturing of the modular tile frame units with factory-affixed tiles is conducted in a controlled, automated environment to ensure precision, repeatability, and product quality. The process begins with the injection molding or extrusion of the frame components, which may be formed as two main halves or four individual legs, depending on the design. These components are produced from rigid, stain-resistant plastics such as polyethylene terephthalate (PET) or polypropylene (PP). Once molded, the frame segments are conveyed to an assembly station, where any necessary quality checks (e.g., dimensional tolerances, surface finish) are performed.
At the assembly station, the frame segments are joined together using integrated mechanical connectors. If the frame is composed of two halves, these are snapped together to form a rigid enclosure. In the four-leg variant, each leg is joined at the corners to complete the rectangular or square perimeter. Cross support bars, if included, are inserted, and locked into place from the underside of the frame to provide structural reinforcement.
The grout replacement column, typically manufactured from semi-flexible thermoplastic polyurethane (TPU), is produced as a separate component. The column is aligned with a dedicated groove along the interior perimeter of the assembled frame and snapped into place. This snap-fit connection ensures a continuous, resilient joint around the tile and accommodates minor dimensional variations and thermal expansion.
A robotic adhesive application system dispenses a controlled amount of construction adhesive onto the base of the frame within the interior tile-receiving space. The adhesive is applied in a precise pattern, typically as a series of parallel beads or a full-coverage layer, to ensure uniform bonding strength and minimize voids. The use of automated dispensers guarantees repeatable adhesive volume and placement, which is critical for long-term durability and tile alignment.
Tiles, preferably rectified for dimensional accuracy, are supplied to the assembly line via an automated tile supply system. A robotic arm equipped with vacuum grippers lifts each tile, verifies its orientation and dimensions using machine vision or laser triangulation sensors, and places it within the prepared frame. The tile is pressed firmly into the adhesive and against the placement stops or the corner of the grout column, ensuring exact positioning. In high-volume production, computer vision and real-time feedback systems enable sub-millimeter alignment accuracy, reducing the need for mechanical stops.
After tile placement, the assembly is conveyed through a curing station, where the adhesive is allowed to set under controlled temperature and humidity conditions. Once cured, each unit undergoes quality inspection, which may include visual checks, dimensional verification, and mechanical testing of the tile-to-frame bond. Any defective units are removed from the production line for rework or recycling. If specified, additional components such as sound dampening pads are inserted into voids on the underside of the frame.
Completed modular tile frame units are stacked, packaged, and prepared for shipment. The packaging process may include protective materials to prevent damage during transport and may be optimized for efficient handling and installation at the project site.
This automated, factory-based manufacturing process ensures that each modular tile frame unit is delivered to the installation site with precisely aligned, securely bonded tiles and all required structural and functional features. The result is a product that minimizes on-site labor, reduces installation errors, and delivers a superior groutless tiled surface.
The modular tile frame system demonstrates a significant advancement over traditional tile installation methods and prior art solutions. By integrating factory-affixed tiles within precision-molded frames, the system delivers consistent alignment, minimal joint widths, and a sleek, modern appearance that is difficult to achieve with conventional techniques. The use of a semi-flexible TPU grout replacement column ensures resilient, moisture-resistant joints that accommodate minor tile variations and thermal expansion, while cross support bars provide robust structural reinforcement, particularly for floating floor applications. The modular design, featuring intuitive male and female connectors, allows for rapid, tool-free assembly and disassembly, supporting a variety of tile patterns and installation configurations. Altogether, this system addresses the longstanding challenges of grout maintenance, installation complexity, and durability, offering a user-friendly, aesthetically superior, and maintenance-friendly solution for groutless hard tile surfaces.
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 system comprising:

a tile frame unit comprising four sides and a plurality of mechanical connectors disposed on the four sides, the plurality of mechanical connectors positioned to enable end-to-end and side-to-side connection of the tile frame unit to an adjacent tile frame unit at each of the four sides, wherein the four sides define an interior space;

a tile factory-affixed to the tile frame unit within the interior space; and

a column factory-affixed to two of the four sides of the tile frame unit.

2. The tile frame unit system of claim 1, wherein the tile frame unit comprises two segments that join together, through mechanical connectors, to form the tile frame unit.

3. The tile frame unit system of claim 1, wherein the tile frame unit comprises four segments, each segment forming one side of the tile frame unit with adjacent segments that joint together, through mechanical connectors, to form the tile frame unit.

4. The tile frame unit system of claim 1, wherein the column comprises two pieces each of which is factory-affixed to a side by snapping into a dedicated groove.

5. The tile frame unit system of claim 4, wherein the two pieces are manufactured as grout replacement pieces from thermoplastic polyurethane (TPU).

6. The tile frame unit system of claim 1, further comprising at least one mud flap disposed on a base of at least one side, the mud flap configured to divert thinset mortar away from a portion of the plurality of mechanical connectors during installation.

7. The tile frame unit system of claim 1, wherein the plurality of mechanical connectors comprises male connectors on a first side and a first end of the frame, and female connectors are positioned on a second side and a second end of the frame.

8. The tile frame unit system of claim 1, further comprising at least two cross support bars configured to provide structural reinforcement.

9. The tile frame unit system of claim 1, further comprising a sound dampening pad positioned within a void on the underside of the tile frame unit.

10. An interlocking modular tile frame system comprising:

a tile frame unit comprising four sides and a plurality of mechanical connectors disposed on the four sides, the plurality of mechanical connectors positioned to enable end-to-end and side-to-side connection of the tile frame unit to an adjacent tile frame unit at each of the four sides, wherein the four sides define an interior space configured to receive a tile; and

a column affixed to two of the four sides of the tile frame unit.

11. The tile frame unit system of claim 10, wherein the tile frame unit comprises two segments that join together, though mechanical connectors, to form the tile frame unit.

12. The tile frame unit system of claim 10, wherein the tile frame unit comprises four segments, each segment forming one side of the tile frame unit with adjacent segments that joint together, through mechanical connectors, to form the tile frame unit.

13. The tile frame unit system of claim 10, wherein the column comprises two pieces each of which is factory-affixed to a side by snapping into a dedicated groove.

14. The tile frame unit system of claim 13, wherein the two pieces are manufactured as grout replacement pieces from thermoplastic polyurethane (TPU).

15. The tile frame unit system of claim 10, wherein the plurality of mechanical connectors comprise male connectors on a first side and a first end of the frame, and female connectors are positioned on a second side and a second end of the frame.

16. The tile frame unit system of claim 10, further comprising at least two cross support bars configured to provide structural reinforcement.

17. A method for installing a tiled surface, comprising:

providing a plurality of interlocking modular tile frame units, each frame unit comprising a rigid or semi-rigid enclosure formed of at least two or more segments, each segment having a base and a column, the columns forming a perimeter on two of the segments and around an interior space, and a plurality of mechanical connectors disposed on outer portions of the two or more segments;

factory-affixing a hard tile within the interior space of each interlocking modular tile frame unit frame unit;

positioning a first row of the interlocking modular frame units along a wall, removing a portion of the plurality of mechanical connectors adjacent to the wall; and

installing subsequent rows by aligning the male connectors of each frame unit with the female connectors of an adjacent frame unit and snapping the units together to form a continuous, groutless tiled surface.

18. The method of claim 17, further comprising inserting cross support bars into the underside of each frame unit for structural reinforcement.

19. The method of claim 17, further comprising inserting a sound dampening pad into the underside of each frame unit.

20. The method of claim 17, utilizing mud flaps on the frame units to divert mortar away from the connectors during installation.