Integrated modular frames with factory-affixed tiles for groutless tiling

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.

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.