# US 2008/0184646 A1 · Groutless tile system and method for making the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2008/0184646 A1 - Document ID: US20080184646A1 - Status: Published application - Kind: A1 - Application number: 11/701,777 - Filed: 2007-02-02 - Published: 2008-08-07 - Earliest claimed: 2007-02-02 - Assignees: Mohawk Carpet Corporation - Inventors: Tom Alford; Mark Cappelle - Web page: https://patentgrep.com/patent/US20080184646A1 ## CPC - E04F 13/14: stone or stone-like materials, e.g. ceramics {concrete,}; of glass {or with an outer layer of stone or stone-like materials or glass (E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00)} - E04F 15/02: Flooring or floor layers composed of a number of similar elements (of webs E04F15/16) - E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements} - E04F 15/087: {The lower layer being of organic plastic with or without reinforcements or filling materials} - E04F 2201/0115: with snap action of the edge connectors - E04F 2201/0153: by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement - Y10T 29/49861: Sizing mating parts during final positional association - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A groutless tile system including: a plurality of groutless tiles, wherein each groutless tile includes: a durable surface disposed on a substrate; and a first coupling member disposed on an edge of the substrate; wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and a second coupling member of an adjacent tile are operable for coupling adjacent groutless tiles, and wherein the substrate prevents the durable surfaces of adjacent groutless tiles from contacting one another. ## Claims ### Claim 1 A groutless tile system comprising: a plurality of groutless tiles, wherein each groutless tile comprises: a durable surface disposed on a substrate; and a first coupling member disposed on an edge of the substrate; wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and a second coupling member of an adjacent tile are operable for coupling adjacent groutless tiles, and wherein at least at least a portion of the first coupling member is disposed below the durable surface of the adjacent tile when coupled to the adjacent tile. ### Claim 2 (depends on 1) The groutless tile system of claim 1, wherein the first coupling member further comprises a first bendable portion and a groove operable for coupling the first coupling member to the second coupling member. ### Claim 3 (depends on 2) The groutless tile system of claim 2, wherein the second coupling member further comprises a tongue and a body portion operable for coupling the first coupling member to the second coupling member. ### Claim 4 (depends on 1) The groutless tile system of claim 1, wherein the first coupling member, the durable surface, and the second coupling member of the groutless tile form a continuous surface. ### Claim 5 (depends on 1) The groutless tile system of claim 1, wherein at least a portion of the substrate is designed to have a texture and color similar to that of grout. ### Claim 6 (depends on 1) The groutless tile system of claim 1, wherein the durable surface is partially encapsulated in the substrate thru the RIM process. ### Claim 7 (depends on 1) The groutless tile system of claim 1, wherein the plurality of groutless tiles further comprise a layment layer disposed on a surface of the substrate opposite of the durable surface. ### Claim 8 (depends on 3) The groutless tile system of claim 3, wherein the first bendable portion of the first coupling member is operable for engaging the body of the second coupling member. ### Claim 9 (depends on 1) The groutless tile system of claim 1, wherein a lateral forces is used to couple the first coupling member and a second coupling member ### Claim 10 A groutless tile comprising: 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 another 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. ### Claim 11 (depends on 10) The groutless tile of claim 10, wherein the first coupling member further comprises a first bendable portion and a groove and wherein the second coupling member further comprises a tongue and a body portion. ### Claim 12 (depends on 11) The groutless tile of claim 11, wherein the first bendable portion of the first coupling member is operable for engaging the body of the second coupling member. ### Claim 13 (depends on 10) The groutless tile of claim 10, wherein the first coupling member, the durable surface, and the second coupling member of the groutless tile form a continuous surface. ### Claim 14 (depends on 10) The groutless tile of claim 10, wherein at least a portion of the substrate is designed to have a texture and color similar to that of grout. ### Claim 15 A method for making a groutless tile comprising: 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 another edge of the substrate. ### Claim 16 (depends on 15) The method of claim 15, wherein the first coupling member further comprises a first bendable portion and a groove and wherein the second coupling member further comprises a tongue and a body portion. ### Claim 17 (depends on 15) The method of claim 15, wherein affixing the durable surface to the substrate is carried out simultaneously with said step of molding said substrate. ### Claim 18 (depends on 15) The method of claim 15, wherein molding said substrate is carried out by molding a substrate through a Reaction Injection Molding (RIM) process, thereby at least partially encapsulating said durable surface by said molded substrate and/or thereby affixing said durable surface to said molded substrate. ### Claim 19 A groutless tile system comprising: a plurality of groutless tiles, wherein each groutless tile comprises: a durable surface disposed on a substrate; a first coupling member disposed on at least one edge of the substrate, the first coupling member comprising a first bendable portion and a groove; and a second coupling member disposed on at least one edge of the substrate, the second coupling member comprising a tongue and a body portion, wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and the second coupling member of an adjacent tile are operable for coupling adjacent groutless tiles, and wherein at least a portion of the first bendable portion of the second coupling member is disposed below the durable surface of the adjacent tile when coupled to the adjacent tile. ### Claim 20 (depends on 19) The groutless tile system of claim 19, wherein the first coupling member and the second coupling member couple adjacent groutless tiles and prevent both horizontal and vertical movement of the groutless tiles. ### Claim 21 (depends on 19) The groutless tile system of claim 19, wherein the first coupling member and the second coupling member extend an entire length of the edge of the substrate.