Mechanically-held tile

A self-grouting tile for a self-grouting tile system, each self-grouting tile comprising:

• a tile portion having design dimensions of a width x, a length y, and a thickness z, and actual dimensions of a width x+δx, a length y+δy, and a thickness z+δz, where δx, δy, and δz each represent a manufacturing deviance from x, y, and z, respectively, and δx ranges from −0.01x to 0.01x, δy ranges from −0.01y to 0.01y and δz ranges from −0.05z to 0.05z, the self-grouting tile further including a mechanical anchoring region formed therein;
• a tile support structure surrounding all edges of the tile portion to create a tile self-grouting portion, the tile self-grouting portion integrally formed with a tile base support portion, the tile self-grouting portion having a design width and length of tx and ty respectively such that, in the x-y horizontal plane of the tile portion a self-grouting tile design dimension is x+tx and y+ty, and due to the manufacturing deviance of the tile, the actual self-grouting portion width in the x direction is tx−δx and the actual length in the y direction is ty−δy, the tile base support portion of the tile support structure having a vertical design thickness of tz, and an actual thickness of tz−δz such that the self-grouting tile design dimensions in the x, y, and z directions are substantially achieved regardless of any manufacturing deviance of the tile;
• and
• the tile support structure self-grouting portion or the tile base support portion mechanically engaging with the tile through the mechanical anchoring region in the tile and wherein the tile support structure further including coupling regions for facilitating interconnection with adjacent self-grouting tiles.

A method for making a mechanically-held composite tile comprising

• providing a tile having a durable surface, an underside and an anchoring region;
• locating the tile in a moulding apparatus, the moulding apparatus having protrusions and recesses extending laterally in a mould at the underside of the tile, said protrusions and recesses being arranged to form coupling regions in a substrate;
• injecting a flowable material into said mould to form a substrate disposed proximal to the underside of the tile;
• arranging said flowable material to contact said tile anchoring region to mechanically anchor the substrate directly on the tile;
• injecting a flowable material into said mould to form a looping member as a grout gasket extending around a periphery of the tile and mechanically engaging the anchoring region, with at least a portion of the looping member extending into contact with an engagement region of the substrate to exert a holding force on the substrate and tile,
• wherein said underside of the substrate further providing the engagement region is accessed by through-channels in said substrate, and
• wherein a plurality of portions of said looping member comprises an interconnected underlayment structure in engagement with said engagement region.

A method of making a mechanically-held self-grouting tile for a self-grouting tile system comprising:

• providing a tile portion having design dimensions of a width x, a length y, and a thickness z, and actual dimensions of a width x+δx, a length y+δy, and a thickness z+δz, where δx, δy, and δz each represent a manufacturing deviance from x, y, and z, respectively, and δx ranges from −0.01x to 0.01x, δy ranges from −0.01y to 0.01y and δz ranges from −0.05z to 0.05z, the self-grouting tile further including an underside and a mechanical anchoring region formed therein;
• positioning the tile portion in a mould;
• injecting a first flowable material into said mould, which flows into contact and mechanically engages with the anchoring region, the first flowable material solidifying into a tile support structure surrounding all edges of the tile portion to create a tile self-grouting portion, the tile self-grouting portion integrally formed with a tile base support portion, the tile self-grouting portion having a design width and length of tx and ty respectively such that, in the x-y horizontal plane of the tile portion a self-grouting tile design dimension is x+tx and y+ty, and due to the manufacturing deviance of the tile, the actual self-grouting portion width in the x direction is tx−δx and the actual length in the y direction is ty−δy, the tile base support portion of the tile support structure having a vertical design thickness of tz, and an actual thickness of tz−δz such that the self-grouting tile design dimensions in the x, y, and z directions are substantially achieved regardless of any manufacturing deviance of the tile;
• and
• the tile support structure self-grouting portion or the tile base support portion mechanically engaging with the tile through the mechanical anchoring region in the tile and wherein the tile support structure further including coupling regions for facilitating interconnection with adjacent self-grouting tiles.