Abstract:
A method for making a groutless tile including: providing a durable surface; molding a substrate to receive at least a portion of the durable surface; affixing the durable surface to the substrate; and milling at least a portion of the substrate to create a first coupling member on an edge of the substrate and a second coupling member on a opposing edge of the substrate.

Description:
CROSS-REFERENCE TO RELATED APPLICATION &amp; PRIORITY CLAIM 
       [0001]    This application is a division of U.S. patent application Ser. No. 11/701,777, filed Feb. 2, 2007, and entitled “Groutless Tile System And Method For Making The Same,” which is incorporated herein by reference in its entirety as if fully set forth below. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to floor and wall covering tiles. More particularly, it relates to a tile system that does not require a grout compound to be applied to the tiles after installation. 
         [0004]    2. Description of Related Art 
         [0005]    Ceramic tiles are widely used as a floor and wall covering in both residential and commercial applications. Tile is very versatile, and has been in use as a floor and wall covering for centuries. Tiles are available in a nearly unlimited color palette and may be installed in an equally unlimited number of designs. Tile is often a top choice for floor and wall coverings because of its great durability and aesthetic qualities. While many tiles are manufactured from ceramic compositions (baked clay), they may be made of a variety of natural or synthetic materials including, but not limited to, granite, quartz, marble, soapstone, plastic, wood, or a other suitable material. 
         [0006]    Tile provides a durable surface and may be coated to be substantially impervious to water and other liquids. When tiles are installed, they are generally laid side by side on a surface such as a floor or wall. Typically, an adhesive compound is used as a base to attach the tiles to a surface and then grout is spread over and between the tiles to further bind the tiles to the surface and to fill spaces between adjacent tiles. While not impervious to water and moisture, the grout provides a barrier to reduce moisture between and behind the tiles. This step of grouting the tiles is labor intensive and represents a significant portion of the labor involved in a typical tile installation. 
         [0007]    Due to the time and labor involved in tile installation, it is typically quite costly to have tile professionally installed. Accordingly, many homeowners desire to install tile in their own homes. Unfortunately, this is an extremely tedious process, and many homeowners do not wish to spend the time necessary for a satisfactory installation. 
         [0008]    In recent years, manufacturers have attempted to produce do-it-yourself tile solutions that are easier to install. One such attempt is described in United States Publication Number US 2004/0031226 entitled “Pre-glued Tongue and Groove Flooring” by Miller et al. Disclosed therein is a laminated “tile” that uses a pre-applied glue for fastening the tiles together. While this system is easier to install than traditional tiles, it still requires a separate grout to be applied and uses a laminate material rather than a solid tile. A laminate material is not likely to be as durable as more traditional materials such as ceramic or stone tiles. Additionally, because the tile system makes use of a laminated structure that is susceptible to moisture damage, the installer is required to apply a messy grout composition to the tiles as part of the installation process. 
         [0009]    A previous attempt to produce an easy to install tile is described in U.S. Pat. No. 2,693,102 entitled “Interlocking Wall Tile.” The &#39;102 patent describes a synthetic wall tile system that snaps together. Unfortunately, this tile is not practicable with substantially ridged materials, such as ceramic, granite, or marble. The Luster et al. tiles are molded into a uniform structure of a single material and rigid materials could not be formed into an operable tab structure as taught in the patent. Such a limitation severely limits the aesthetic qualities available for the tiles and thereby reduces the marketability of the system. 
         [0010]    Accordingly, there is a need in the art for a tile system that is simple to install. 
         [0011]    Additionally, there is a need in the art for a tile system that does not require a grout to be applied to the tiles after installation. 
         [0012]    Further, there is a need in the art for an easy to install tile system that makes use of durable tile materials. 
         [0013]    In addition, there is a need in the art for a tile system that primarily utilizes traditional tile materials, but eliminates the need for grout. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    Briefly, described herein is a tile having at least one coupling member that cooperatively engages a coupling member of an adjacent tile, such that adjacent tiles can be reasonably secured to one another without the use of grout. In one exemplary embodiment, cooperative coupling members are a male-type coupling members and female-type coupling members that are designed to secure adjacent tiles. 
         [0015]    In exemplary embodiments, a wide variety of tiling systems may be used. For example, in one exemplary tiling system individual tiles may include all male-type or all female-type coupling members. In another example, the individual tiles may include two male-type coupling members and two female-type coupling members located on either adjacent or opposing edges of the tiles. In yet another example, the individual tiles may have another combination of male-type and female-type coupling members disposed on one or more of the edges of the tiles. The above examples are only intended as illustrations and are not intended to be limiting in any way; on the contrary, a wide variety of alternative exemplary embodiments would be understood to a person of ordinary skill in the art. 
         [0016]    Disclosed herein is a groutless tile system including: a plurality of groutless tiles, wherein each groutless tile includes: a durable surface disposed on a substrate; a first coupling member disposed on an edge of the substrate; and a second coupling member disposed on an opposing edge of the substrate, wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and the second coupling member of the groutless tiles are operable for coupling adjacent groutless tiles, and wherein the substrate maintains spacing between the durable surfaces of adjacent groutless tiles. 
         [0017]    Also disclosed herein is a groutless tile including: a durable surface disposed on a substrate; a first coupling member disposed on an edge of the substrate; and a second coupling member disposed on an opposing edge of the substrate, wherein the first coupling member and the second coupling member of the substrate extend beyond the durable surface, wherein the first coupling member and the second coupling member of the groutless tile are operable for coupling the groutless tile to an adjacent groutless tile, and wherein at least a portion of the substrate extends vertically to form a substantially continuous surface with the durable surface. 
         [0018]    Further disclosed herein is a method for making a groutless tile including: providing a durable surface; molding a substrate to receive at least a portion of the durable surface; affixing the durable surface to the substrate; and milling at least a portion of the substrate to create a first coupling member on an edge of the substrate and a second coupling member on a opposing edge of the substrate. 
         [0019]    Still further disclosed herein is a floor covering consisting of floor elements including at least a synthetic support structure and a decorative element selected form the group consisting of natural stone, terracotta, ceramic tile and synthetic stone; the decorative element being supported, either directly or indirectly, by the support structure and at least partially defining the upper side of the floor element; the support structure at least at a first pair of two opposite sides including coupling parts, which are realized substantially as a male coupling part and a female coupling part, which are provided with vertically active locking portions, which, when the coupling parts of two of such floor elements cooperate with each other, effect a locking in a vertical direction and also are provided with horizontally active locking portions, which, when the coupling parts of two of such floor elements cooperate with each other, effect a locking in horizontal direction whereby the coupling parts are of the type allowing that two of such floor elements can be connected to each other at the sides by engaging one of these floor elements with the associated male coupling part, by means of a rotational and/or planer motion, in the female coupling part of the other floor element; wherein the male coupling part projects at least partially beyond the upper edge of the concerned side. In a preferred embodiment said horizontally active locking portion, in a coupled condition of two such floor elements or tiles, is located vertically under a durable surface of at least one of said tiles. Said durable surface is preferably formed by said decorative element. In another or the same preferred embodiment said vertically active locking portions can substantially have the shape of a tongue and a groove, which in a coupled condition of two of such floor elements or tiles, preferably, wholly or partially, engage vertically under a portion of the synthetic support structure or substrate, whereby this portion of the substrate extends horizontally beyond said durable surface or said decorative element of at least one of said tiles. It is possible that contact surfaces are formed between the tongue and the groove, said contact surfaces preventing or limiting vertical motion of two tiles or floor elements in a coupled condition thereof. At least one of said contact surfaces, being located at the top side of the tongue, is preferably located in a plane, e.g. a horizontal plane, which intersects the decorative element forming said durable surface. Instead of being located in a plane, the concerned contact surface might also show a point of contact which is located the closest to the durable surface and which is located in a horizontal plane which intersects the decorative element forming said durable surface. 
         [0020]    Also disclosed herein is a method for manufacturing floor elements including at least a synthetic support structure and a decorative element selected from the group consisting of natural stone, terracotta, ceramic tile and synthetic stone; the decorative element being supported, either directly or indirectly, by the support structure and at least partially defining the upper side of the floor element; the support structure having edge portions; the edge portions at least at two opposite sides of the support structure having coupling parts; wherein the method at least includes the following two successive steps: the step of providing a semi-finished product including at least the aforementioned support structure and the aforementioned decorative element; the step of performing a machining treatment on at least an edge portion of the already formed semi-finished product, more particularly on the edge portions of the support structure of the semi-finished product, in order to manufacture at least part of the coupling parts to be formed therein. 
         [0021]    These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0023]      FIG. 1  is a perspective view illustration of a tile in accordance with an exemplary embodiment of the present invention; 
           [0024]      FIG. 2  is a cross-sectional view illustration of another tile in accordance with an exemplary embodiment of the present invention; 
           [0025]      FIG. 3  is a cross-sectional view illustration of two adjacent tiles in accordance with an exemplary embodiment of the present invention; and 
           [0026]      FIG. 4  is an illustration of a method for making a tile in accordance with an exemplary embodiment of the present invention. 
       
    
    
       [0027]    The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0028]    As used herein, the term “disposed” generally means located either at or upon. Additionally, the term disposed is intended to include an element integrally or detachableably connected to another element as well as object simple placed on another element. Furthermore, it will be understood that when an element is referred to as being “disposed on” another element, it can be directly on the other element or intervening elements may be present there between. In contrast, when an element is referred to as being “disposed directly on” another element, there are no intervening elements present. 
         [0029]    Referring now to  FIG. 1 , a groutless tile in accordance with an exemplary embodiment of the present invention is generally depicted as  100 . The groutless tile  100  includes a durable surface  102  that is disposed on a substrate  104 . In exemplary embodiments, the durable surface  102  may be affixed to the substrate  104  using a wide variety of methods such as the use of an adhesive. The durable surface  102  may be a ceramic composition (baked clay), or it may be made of a variety of natural or synthetic materials including, but not limited to, granite, quartz, marble, soapstone, plastic, wood, or another suitable material. Likewise, the substrate  104  may be a made of a suitable polymeric material. In exemplary embodiments, the substrate  104  may be constructed of a suitable material that is chemical resistant, stain resistant, non-porous, and formable to within sufficient precision. While the groutless tile  100  is depicted in a square shape, it will be clear that alternate shape groutless tiles such as hexagon, octagon, or the like are also contemplated. 
         [0030]    In exemplary embodiments, the substrate  104  is designed to have larger dimensions than the durable surface  102  such that the durable surface  102  may be disposed within a groove defined by the substrate  104 . In one embodiment, the top surface of the durable surface  102  and the top surface of the substrate  104  may form a continuous surface. The substrate  104  includes a flange portion  106  that is disposed along the edges of the substrate  104 . The flange portion  106  further includes a first coupling member  120  and a second coupling member  140 , which may be disposed on opposing or adjacent sides of the groutless tile  100 . The first coupling member  120  and the second coupling member  140  are designed such that they are operable for coupling together one or more adjacent groutless tiles  100 . 
         [0031]    In exemplary embodiments, the groutless tile  100  may include an underlayment layer that may act as a moisture or sound barrier. Additionally, the underlayment may serve a surface leveling function. Further, the underlayment may serve as an adhesive for attaching the tiles to an installation surface, such as a floor or a wall. The composition of the underlayment layer may depend upon the intended purpose of the underlayment layer. In exemplary embodiments, the underlayment layer may be a multilayered layment composed of several distinct layers each designed to perform a specific function. The underlayment may be secured to substrate  104  of the groutless tile  100  through the use of an adhesive or another suitable means. 
         [0032]    In an exemplary embodiment, at least a portion of the flange portion  106 , may be of polymeric material and preferably is a polyurethane material, such as ELASTOCASTr70654 by BASF®. ELASTOCASTr70654 is an unpigmented, 77 to 79 Shore D urethane elastomer designed for cross-sections up to three inches, which has some inherent tackiness. It is also contemplated that another polymeric material may be used in flange portion  106 . The following data may be helpful in producing the material used in a flange portion  106  in accordance with an exemplary embodiment. This data is provided for example only, and is not intended to limit the scope of the invention. Other compositions may also be used to fabricate the flange portion  106 . 
         [0000]    
       
         
               
               
             
               
               
               
             
               
               
             
               
               
               
             
           
               
                   
               
             
             
               
                 Mix Ratio @ 105 index: 
                 100 parts of ELASTOCASTr7065R Resin 
               
               
                   
                 771. parts of WUC 3192T ISOCYANATE 
               
             
          
           
               
                 Specific Gravity: 
                 Resin 
                 1/048 f/cc, 8.72 lbs./gal. @ 77° F. 
               
               
                   
                 Iso 
                 1.22 g/cc, 10.2 lbs./gal. @ 77° F. 
               
               
                 Viscosity: 
                 Resin 
                 1220 cps @ 77° F. 
               
               
                   
                 Iso 
                 200 cps @ 77° F. 
               
             
          
           
               
                 Typical Reactivity: 
                 Hand mixed at 86° F. at 105 index 
               
               
                   
                 Gel time: 180 to 240 seconds 
               
             
          
           
               
                 Recommended processing 
                 Component temperatures: 
                 Resin 75-95° F. 
               
               
                 conditions: 
                   
                 Iso 75-95° F. 
               
               
                   
                 Mold temperature: 
                 130-160° F. 
               
               
                   
                 Demold time: 
                 10-20 minutes 
               
               
                   
               
             
          
         
       
     
         [0033]    Alternatively, other polymer variations, such as polyamides, vinyl polymers and polyoletins may be used. Preferably, the flange portion  106  may be made, but is not so limited, from a material that is chemical resistant, stain resistant, non-porous, and formable to within sufficient precision. Additionally, it may be desirable for the flange portion  106  to have sealing qualities so as to impede the intrusion of moisture between and behind the tiles and adherence qualities so as to minimize or present movement or displacement of the tiles. 
         [0034]    Turning now to  FIGS. 2-3  which illustrate the coupling of a first groutless tile  200  with a second groutless tile  300 . A first coupling member  220  and a second coupling member  340  function to connect the first groutless tile  200  and the second groutless tile  300 . The first coupling member  220  of the first groutless tile  200  includes a first bendable portion  222  and a groove  224 . The second coupling member  340  of the second groutless tile  300  includes a tongue  346  and a body portion  348 . The groove  224  of the first coupling member  220  is designed to receive the body portion  348  and the tongue  346  of the second coupling member  340 . Once positioned inside the groove  224  of the first coupling member  220  the body portion  348  and the tongue  346  contacts the first bendable portion  222  and the groove  224 , respectively. In one embodiment, the tongue  346  and the first bendable portion  222  are designed to bend at least the first bendable portion during the coupling of the groutless tile  200  and the second groutless tile  300 . Additionally, the tongue  346  and the first bendable portion  222  are designed such that at least the first bendable portion  222  returns to or towards its normal unbent position once the groutless tile  200  and the second groutless tile  300  are coupled in order to prevent the tiles from separating. A contact surface between said tongue  346  and said groove  224  is also formed at the top side of said tongue  346 , whereby said contact surface is located in a horizontal plane, which intersects the decorative element forming said durable surface  102 . 
         [0035]    Continuing with reference to  FIG. 3 , the first bendable portion  222  includes an enlarged portion on its distal end that has an inclined inner surface  350 . Additionally, the body portion  348  of the second coupling member  340  also includes an inclined surface  360  on its proximal end. The inclined inner surface of the first bendable portion  222  is designed to have a substantially complimentary angle to that body portion  348  of the second coupling member  340 . The first bendable portion  222  is designed to slideably contact the body portion  348  during the coupling of the groutless tile  200  and the second groutless tile  300 . Furthermore, the inclined surfaces of the first bendable portion  222  and body portion  348  are operable for properly positioning and the groutless tile  200  and the second groutless tile  300  during coupling. In exemplary embodiments, the inclined surfaces of the first bendable portion  222  and the body portion  348  function to keep the groutless tile  200  and the second groutless tile  300  properly positioned while the tiles are coupled to one another. Said inclined inner surfaces of both said body portion  348  and said enlarged portion  342  form horizontally active locking portions, which in a coupled condition are located vertically under a durable surface  202 ,  302  of at least one of said tiles  200 - 300 . 
         [0036]    In exemplary embodiments, the tongue  346  is located at the distal end of the second coupling member  340  and extends substantially horizontally and outwardly from the second groutless tile  300 . Said tongue  346  of said second coupling member  340  and said groove  224  of the first coupling member  220  are vertically active locking portions and wholly engage vertically under a portion of the synthetic support structure or substrate  204 ,  304 , whereby this portion of the substrate  104  extends horizontally beyond said durable surface  202 ,  302  or said decorative element of at least one of said tiles  200 - 300 . 
         [0037]    In exemplary embodiments, the first groutless tile  200  may be coupled to the second groutless tile  300  by snapping or pushing the second coupling member  340  of the second groutless tile  300  into the first coupling member  220 . In one embodiment, a lateral or horizontal is necessary to properly couple the first groutless tile  200  and the second groutless tile  300 . Furthermore, during the coupling of the groutless tile  200  and the second groutless tile  300  the second coupling member  340  of the second groutless tile  300  may be locked into position once inserted into the groove  224  of the first coupling member  220 . Additionally, during the coupling of the first groutless tile  200  and the second groutless tile  300  the first bendable portion  222  may be bent to accommodate the insertion of the first body portion  348  into the groove  224 . After the first groutless tile  200  and the second groutless tile  300  are coupled the first bendable portion  222  returns to or towards its normal unbent position and remains in contact with the body portion  348 . In exemplary embodiments, the first groutless tile  200  and the second groutless tile  300  may be separated from one another by pivotally disengaging the first groutless tile  200  from the second groutless tile  300 , preferably without damaging the respective tiles and their coupling members. It is noted that in a completely coupled condition of the respective groutless tiles  200 - 300 , it is possible that the first bendable portion  222  is bent out of the level under surface of said tiles  200 - 300 . Such bending out might create an extra firm coupling especially in the horizontal direction, thereby strongly preventing separation of two coupled tiles in said horizontal direction. 
         [0038]    Turning now to  FIG. 4 , an illustration of a method for making a tile in accordance with an exemplary embodiment of the present invention is generally depicted as  400 . During the first step in the method  400 , a durable surface  402  is provided and inserted into a mold  404 . Once the durable surface  402  has been positioned in the mold  404  a substrate  406  may be formed around a portion of the durable surface  402 . In one embodiment, the substrate  406  may be a plastic material that is injection molded or reaction injection molded (RIM) around the durable surface  402 . The substrate  406  forms around the durable surface  402  to create the groutless tile  408 . Next the groutless tile  408  is processed through a series of tools  410  that are used to create one or more flanges  412  around the edges of the tile  408 . In one embodiment, the tools  410  may perform a milling process with one or more milling cutters that are positioned at different positions and angles with respect to the groutless tile  408 . As shown in  FIG. 4 , the flanges  412  including the first and second coupling members may extend the entire length of one side of the substrate  406  thereby simplifying the milling process. 
         [0039]    While the exemplary embodiments of the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements, which fall within the scope of the claims that follow. These claims should be construed to maintain the proper protection for the invention first described.