TECHNICAL FIELD

The present disclosure relates generally to floor tiles, and more particularly, to a grout- free floor tile.

BACKGROUND

A common method of installing floor tiles in a bathroom, a kitchen, or the like involves grouting, that is, the process of filling spaces between adjacent tiles with grout. Generally a mixture of cement, sand, and water, grout can be manually applied to fill gaps between tiles in order to reinforce the structure there between. Other varieties of grout exist, as well, which can be utilized depending on the application.

Grouting typically entails a laborious multi-step process. First, grout can be applied to newly placed floor tiles using a hard-edged grout float so that the grout fills in the gaps between each tile. Once the grout begins to set, the tiles can be wiped thoroughly with a sponge or cloth, after which a sealer can be spread for protection using a paintbrush or specialized applicator.

Grout can also be available in several colors and thereby contribute to the overall appearance of the floor tiles. Designers often select particular grout mixtures to achieve a desired appearance. However, the process of grouting, as described above, can be both time consuming and expensive.

SUMMARY

The present disclosure provides a grout-free floor tile including an interlocking part disposed along the length of an edge of the tile for interlocking with another interlocking part of an adjacent tile. The tile can further include an indentation portion formed into an upper surface of the tile at a position substantially above the interlocking part. The indentation portion can form a notch that extends along a region at which the tile abuts an adjacent tile. The appearance of the notch can replicate the appearance of traditional grout used to fill a gap between the tiles, without the inconvenience of actually applying grout. The resulting floor tiles can be installed more easily and cost-effectively by eliminating the need for grouting while maintaining the appearance of grouted tiles.

According to embodiments of the present disclosure, a grout-free floor tile can include: a slab including a plurality of edges, an upper surface, and a lower surface; an interlocking part disposed along a length of an edge of the slab and configured to interlock with an adjacent interlocking part disposed along a length of an edge of an adjacent slab, the interlocking part including one of a projecting tongue portion and a receiving groove portion, the adjacent interlocking part including the other of the projecting tongue portion and the receiving groove portion, the receiving groove portion being formed to receive and secure the projecting tongue portion when the slab is brought into abutment with the adjacent slab; and an indentation portion formed into the upper surface of the slab and disposed along the length of the edge of the slab at a position substantially above the interlocking part. When the interlocking part interlocks with the adjacent interlocking part, the indentation portion can form a notch extending along a region at which the slab abuts the adjacent slab.

The adjacent slab can include an adjacent indentation portion formed into an upper surface of the adjacent slab and disposed along the length of the edge of the adjacent slab at a position substantially above the adjacent interlocking part. In this regard, when the interlocking part interlocks with the adjacent interlocking part, an outer end of the indentation portion can be in fluid communication with an outer end of the adjacent indentation portion such that the notch extends across both of the indentation portion and the adjacent indentation portion. Also, a width of the indentation portion can be greater than a width of the adjacent indentation portion.

On the other hand, when the interlocking part interlocks with the adjacent interlocking part, an outer end of the indentation portion can abut the edge of the adjacent slab such that the notch extends along the indentation portion only.

The indentation portion can include a rounded inner portion connecting to the upper surface of the slab. Alternatively, the indentation portion can include an orthogonal inner portion connecting to the upper surface of the slab.

An outward appearance of a surface of the indentation portion can resemble an outward appearance of grout. In some cases, a coating can be disposed on a surface of the indentation portion so as to resemble an outward appearance of grout. Also, an outward appearance of a surface of the indentation portion can differ from an outward appearance of the upper surface of the slab.

The grout-free floor tile can further include another interlocking part disposed along a length of another edge of the slab, the other interlocking part including the other of the projecting tongue portion and the receiving groove portion.

The slab can be made of a stone plastic composite-based material.

Additionally, a width of the indentation portion can be within a range of 2 mm to 10 mm. A thickness of the indentation portion can be within a range of 0.3 mm to 3 mm. A thickness of the slab can be within a range of 8 mm to 30 mm.

Furthermore, in accordance with embodiments of the present disclosure, a grout-free floor tile system can include: a first slab including a plurality of edges, an upper surface, and a lower surface; a first interlocking part disposed along a length of an edge of the first slab, the first interlocking part including one of a projecting tongue portion and a receiving groove portion; a first indentation portion formed into the upper surface of the first slab and disposed along the length of the edge of the first slab at a position substantially above the first interlocking part; a second slab including a plurality of edges, an upper surface, and a lower surface; and a second interlocking part disposed along a length of an edge of the second slab and configured to interlock with the first interlocking part, the second interlocking part including the other of the projecting tongue portion and the receiving groove portion, the receiving groove portion being formed to receive and secure the projecting tongue portion when the first slab is brought into abutment with the second slab. When the first interlocking part interlocks with the second interlocking part, the first indentation portion can form a notch extending along a region at which the first slab abuts the second slab.

The grout-free floor tile system can further include a second indentation portion formed into the upper surface of the second slab and disposed along the length of the edge of the second slab at a position substantially above the second interlocking part. When the first interlocking part interlocks with the second interlocking part, an outer end of the first indentation portion can be in fluid communication with an outer end of the second indentation portion such that the notch extends across both of the first and second indentation portions.

Alternatively, when the first interlocking part interlocks with the second interlocking part, an outer end of the first indentation portion can abut the edge of the second slab such that the notch extends along the first indentation portion only.

Furthermore, in accordance with embodiments of the present disclosure, a method for manufacturing a grout-free floor tile can include: providing a slab including a plurality of edges, an upper surface, and a lower surface; processing the slab a first time, using a tile cutting machine, to form an interlocking part along a length of an edge of the slab, the interlocking part configured to interlock with an adjacent interlocking part disposed along a length of an edge of an adjacent slab, the interlocking part including one of a projecting tongue portion and a receiving groove portion, the adjacent interlocking part including the other of the projecting tongue portion and the receiving groove portion, the receiving groove portion being formed to receive and secure the projecting tongue portion when the slab is brought into abutment with the adjacent slab; and after processing the slab the first time, processing the slab a second time, using the tile cutting machine, to form an indentation portion formed into the upper surface of the slab along the length of the edge of the slab at a position substantially above the interlocking part. When the interlocking part interlocks with the adjacent interlocking part, the indentation portion can form a notch extending along a region at which the slab abuts the adjacent slab.

The method can further include applying a coating to a surface of the indentation portion so as to resemble an outward appearance of grout.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments herein may be better understood by referring to the following description in conjunction with the accompanying drawings in which like reference numerals indicate identically or functionally similar elements, of which:

FIGS. 1A-1G are various perspective views of an exemplary grout-free floor tile including an indentation portion with an orthogonal inner portion;

FIG. 2 is a cross-sectional view of another exemplary grout-free floor tile including an indentation portion with an orthogonal inner portion;

FIG. 3 is a perspective view of an exemplary grout- free floor tile including an indentation portion with a rounded inner portion;

FIG. 4 is a cross-sectional view of another exemplary grout-free floor tile including an indentation portion with a rounded inner portion;

FIGS. 5A and 5B are various perspective views of other exemplary grout-free floor tiles including an indentation portion with an orthogonal inner portion and an indentation portion with a rounded inner portion, respectively;

FIGS. 6A-6D are various perspective views of yet other exemplary grout-free floor tiles including an indentation portion with an orthogonal inner portion; and

FIG. 7 is a flowchart illustrating a simplified, exemplary process for manufacturing a grout- free floor tile.

It should be understood that the above-referenced drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the disclosure. The specific design features of the present disclosure, including, for example, specific dimensions, orientations, locations, and shapes, will be determined in part by the particular intended application and use environment.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present disclosure. Further, throughout the specification, like reference numerals refer to like elements.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,”“an,” and“the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term“and/or” includes any and all combinations of one or more of the associated listed items.

Referring now to embodiments of the present disclosure, the disclosed grout- free floor tile can include an interlocking part disposed along the length of an edge of the tile for interlocking with another interlocking part of an adjacent tile, providing structural stability between tiles without the use of grout. The tile can further include an indentation portion formed into an upper surface of the tile at a position substantially above the interlocking part. The indentation portion can form a notch that extends along a region at which the tile abuts an adjacent tile. The appearance of the notch can replicate the appearance of traditional grout used to fill a gap between the tiles, without the inconvenience of actually applying grout. The resulting floor tiles can be installed more easily and cost-effectively by eliminating the need for grouting while maintaining the appearance and structural integrity of grouted tiles.

FIGS. 1A-1G are various perspective views of an exemplary grout-free floor tile including an indentation portion with an orthogonal inner portion. As shown in FIGS. 1A- 1G, a slab 100 can be provided having a plurality of edges 102 (one edge 102 in particular is shown in FIGS. 1A and 1B), an upper surface 104, and a lower surface 106. The slab 100 can alternatively be referred to herein as a“first slab.” Also, an adjacent slab 200 can be provided having a plurality of edges 202 (one edge 202 in particular is shown in FIGS. 1A and 1B), an upper surface 204, and a lower surface 206. The adjacent slab 200 can alternatively be referred to herein as a“second slab.”

The design of slabs 100 and 200 can vary. For example, the slabs 100 and 200 can be formed in any suitable shape, such as square or rectangle. The thickness‘C’ of each slab 100 and 200 (see FIG. 2) can be within any suitable range, such as a range of 8 mm to 30 mm, for example. The slabs 100 and 200 can be formed of any suitable material, such as ceramic, porcelain, travertine, slate, marble, granite, cement, vinyl, glass, wood, etc., or any combination thereof. In another example, slabs 100 and 200 can be formed of a composite material, such as stone plastic composite (SPC). The SPC can include a series of layers, such as a waterproof core, film and/or wear layers, a protective outer coating, and/or a foam underlayment, as is generally understood in the art.

The slab 100 can interlock with the adjacent slab 200 via an interlocking part 110 disposed along the length of the edge 102. The interlocking part 110 can be configured to interlock with an adjacent interlocking part 210 disposed along the length of the edge 202 of the adjacent slab 200, forming a joint between the two slabs. Thus, when the interlocking part 110 interlocks with the adjacent interlocking part 210, the slabs 100 and 200 can be securely coupled to each other.

In one example, the interlocking part 110 can be formed to interlock with the adjacent interlocking part 210 through a mutual tongue-and-groove structure. For instance, as shown in FIGS. 1A-1G, the interlocking part 110 can include a receiving groove portion, while the adjacent interlocking part 210 can include a projecting tongue portion (or vice versa). The receiving groove portion of the interlocking part 110 can receive and secure the projecting tongue portion of the adjacent interlocking part 210 when the slab 100 is brought into abutment with the adjacent slab 200.

The design of the tongue-and-groove structure of the interlocking part 110 and adjacent interlocking part 210 can vary. For instance, as in the example of FIGS. 1 A-1G, the tongue-and-groove structure can be configured as a“click-fitting” system. Here, features of the interlocking part 110 and adjacent interlocking part 210 can“click” into place and lock together, eliminating the need for adhesives such as glue, screws, nails, etc., and reducing the presence of gaps between the slabs 100 and 200. The specific shape of the interlocking part 110 and adjacent interlocking part 210 can vary, but can include, for instance, complementary hook-like shapes, as well as tapered outer edges allowing for the tongue portion to be pushed into and received by the groove portion.

Alternatively, as in the example of FIGS. 5A and 5B, the tongue-and-groove structure can be configured in a“traditional” manner. Here, features of the interlocking part 510 and adjacent interlocking part 610 can fit together to create a smooth, gapless flooring arrangement. The slabs 500 and 600 can be secured by nails, screws, or glue, or can be floated over an underlay, as is generally known in the art. Again, the specific shape of the interlocking part 510 and adjacent interlocking part 610 can vary, but can include, for instance, complementary rectangular or square-shaped projections or indentations.

Each slab 100 and 200 can also include one or more additional interlocking part (not shown) disposed along a length of another edge of the slab. Each additional interlocking part can be configured either in the same manner as the interlocking part 110, or in a manner opposite thereto. In the latter case, for example, if the interlocking part 110 includes a receiving groove portion, as shown in FIGS. 1A-1G, an additional interlocking part can instead include a projecting tongue portion.

It should be understood that although FIGS. 1A-1G appear to show an arrow pointing to a specific portion of the tongue and groove structure as corresponding to the interlocking part 110 (and similarly the adjacent interlocking part 210), the interlocking part 110 may actually correspond either to the entire structure disposed at the edge of the slab 100 designed to interlock with the adjacent interlocking part 210, or to any particular component(s) thereof.

The slab 100 can further include an indentation portion 120 formed into the upper surface 104 of the slab 100. The indentation portion 120 can be disposed along the length of the edge 102, such that the indentation portion is positioned substantially above the interlocking part 110, as shown in FIGS. 1A-1G.

Notably, the indentation portion 120 can mimic the appearance of a grout line extending along the joint between the slabs 100 and 200. When the interlocking part 110 interlocks with the adjacent interlocking part 210, the indentation portion 120 can form a notch 125 extending along the region (or joint) at which the slab 100 abuts the adjacent slab 200. The notch 125 can mimic the look or appearance of a grout line by having an outward appearance similar to that of grout. For instance, the outer surface of the indentation portion 120 can be colored and/or textured in a manner which resembles the color and/or texture of grout. In some examples, a coating (e.g., paint, stain, etc.) can be applied to a surface of the indentation portion 120 so as to resemble the outward appearance of grout. In other examples, no such outer coating is necessary. The outward appearance of the surface of the indentation portion 120 can differ from that of the upper surface 104 of the slab 100 to distinguish the notch 125 from the rest of the tile to further imitate the appearance of a grout line extending along the edge 102 of the slab 100.

Because the notch 125 extending along the joint of the slabs 100 and 200 can mimic the appearance of a grout line, a flooring tile system can be installed without the hassle of actually spreading grout between tiles, while maintaining the look of grouted tiles.

Additionally, the resulting floor tile system can achieve the structural integrity of grouted tiles without the use of grout by way of the tongue-and-groove attachment means 110 and 210.

The design of the indentation portion 120 can vary. For instance, the width‘A’ of the indentation portion 120 (see FIG. 2) can be within any suitable range, such as a range of 2 mm to 10 mm, for example. Similarly, the thickness Έ’ of the indentation portion 120 (see FIG. 2) can be within any suitable range, such as a range of 0.3 mm to 3 mm, for example.

The shape of the indentation portion 120 can also vary. In one example, the indentation portion 120 can include an orthogonal inner portion 130 connecting to the upper surface 104 of the slab 100, as shown in FIGS. 1A-1G. Here, the inner end of the indentation portion 120 can form an orthogonal or 90-degree angle extending to the upper surface 104.

In another example, the indentation portion 320 (corresponding, in essence, to indentation portion 120) can include a rounded inner portion 330 connecting to the upper surface 304 of the slab 300, as shown in FIG. 3, described in greater detail below. Here, the inner end of the indentation portion 320 can form a rounded or tapered portion extending to the upper surface 304.

In some examples, an outer end of the indentation portion 120 can abut the edge 202 of the adjacent slab 200. Here, it can appear that the notch 125 extend along the indentation portion 120 of the slab 100 only. In other examples, however, the adjacent slab can include an adjacent indentation portion configured to be operatively coupled with the indentation portion 120.

In this regard, FIG. 2 is a cross-sectional view of another exemplary grout-free floor tile including an indentation portion with an orthogonal inner portion. As shown in FIG. 2, an adjacent slab 250 (corresponding, in essence, to adjacent slab 200) can include an adjacent indentation portion 260 formed into the upper surface 254 of the adjacent slab 250. Like the indentation portion 120, the adjacent indentation portion 260 can be disposed along the length of the edge of the adjacent slab 250 at a position substantially above the adjacent interlocking part of the adjacent slab 250. In some examples, the indentation portion 120 can extend outwardly further than the adjacent indentation portion 260. That is, the width of the indentation portion 120 can be greater than the width of the adjacent indentation portion 260.

When the interlocking part 110 interlocks with the adjacent interlocking part 210, an outer end of the indentation portion 120 can be in fluid communication with an outer end of the adjacent indentation portion 260, as shown in FIG. 2. That is, the upper surface of the indentation portion 120 can be flush with the upper surface of the adjacent indentation portion 260, thus giving the appearance of a seamless notch. Accordingly, the notch 125 can extend either across both of the indentation portion 120 and the adjacent indentation portion 260 of the slab 100 and slab 250, respectively, or along the indentation portion 120 of the slab 100 only as illustrated in FIGS. 1A-1G.

As briefly mentioned above, FIG. 3 is a various perspective view of an exemplary grout- free floor tile including an indentation portion with a rounded inner portion. As shown in FIG. 3, the slab 300 can interlock with the adjacent slab 400 via an interlocking part 310 disposed along the length of the edge 302 and an adjacent interlocking part 410 disposed along the length of the edge 402 of the adjacent slab 400, forming a joint between the two slabs, in a manner identical to slabs 100 and 200. The slab 300 can also include an indentation portion 320 similar to the indentation portion 120.

In contrast to the indentation portion 120, however, the indentation portion 320 can include a rounded inner portion 330 connecting to the upper surface 304 of the slab 300. Here, the inner end of the indentation portion 320 can form a rounded or tapered portion extending to the upper surface 304, as opposed to the orthogonal inner portion 130.

The rounded inner portion 330 is further illustrated in FIG. 4, which is a cross- sectional view of another exemplary grout-free floor tile including an indentation portion with a rounded inner portion. In a manner similar to the adjacent slab 250, the adjacent slab 450 (corresponding, in essence, to adjacent slab 400) can include an adjacent indentation portion 460 formed into the upper surface 454 of the adjacent slab 450. Like the indentation portion 320, the adjacent indentation portion 460 can be disposed along the length of the edge of the adjacent slab 450 at a position substantially above the adjacent interlocking part of the adjacent slab 450. In some examples, the indentation portion 320 can extend outwardly further than the adjacent indentation portion 460. That is, the width of the indentation portion 320 can be greater than the width of the adjacent indentation portion 460.

When the interlocking part 310 interlocks with the adjacent interlocking part 410, an outer end of the indentation portion 320 can be in fluid communication with an outer end of the adjacent indentation portion 460, as shown in FIG. 2. That is, the upper surface of the indentation portion 320 can be flush with the upper surface of the adjacent indentation portion 460, thus giving the appearance of a seamless notch. Accordingly, the notch 325 can extend either across both of the indentation portion 320 and the adjacent indentation portion 460 of the slab 300 and slab 450, respectively, or along the indentation portion 320 of the slab 300 only as illustrated in FIG. 3.

As briefly mentioned above, FIGS. 5A and 5B are various perspective views of other exemplary grout- free floor tiles including an indentation portion with an orthogonal inner portion and an indentation portion with a rounded inner portion, respectively. As shown in FIGS. 5A and 5B, the tongue- and-groove structure of the interlocking part 510 and 710 of slabs 500 and 700, respectively, and the adjacent interlocking part 610 and 810 of slabs 600 and 800, respectively, can be configured in a“traditional” manner. The specific shape of the interlocking part 510/710 and adjacent interlocking part 610/810 can vary, but can include, for instance, complementary rectangular or square-shaped projections or indentations, such that the interlocking part 510/710 and adjacent interlocking part 610/810 fit together to create a smooth, gapless flooring arrangement.

Each of slabs 500 and 700 can respectively include an indentation portion 520 and 720 similar to indentation portions 120 and 320. In one example, the indentation portion 520 can include an orthogonal inner portion 530 connecting to the upper surface 504 of the slab 500. In another example, the indentation portion 720 can include a rounded inner portion 730 connecting to the upper surface 704 of the slab 700. As explained above, when the interlocking part 510/710 interlocks with the adjacent interlocking part 610/810, the indentation portions 520 and 720 can form a notch 525 and 725, respectively, extending along the region (or joint) at which the slab 500/700 abuts the adjacent slab 600/800. The notch 525/725 can mimic the look or appearance of a grout line by having an outward appearance similar to that of grout. Slabs 600 and 800 can also include indentation portions in some cases, whereby the notch can extend across both slabs when the interlocking part 510/710 interlocks with the adjacent interlocking part 610/810, thus modifying the appearance of the resulting notch.

FIGS. 6A-6D are various perspective views of yet other exemplary grout-free floor tiles including an indentation portion with an orthogonal inner portion. As shown in FIGS. 6A-6D, the slab 900 can interlock with the adjacent slab 1000 via an interlocking part 910 disposed along the length of the edge of the slab 900 in a manner similar to the exemplary floor tiles described hereinabove. The interlocking part 910 can be configured to interlock with an adjacent interlocking part 1010 disposed along the length of the edge of the adjacent slab 1000, forming a joint between the two slabs. Thus, when the interlocking part 910 interlocks with the adjacent interlocking part 1010, the slabs 900 and 1000 can be securely coupled to each other.

In one example, the interlocking part 910 can be formed to interlock with the adjacent interlocking part 1010 through a mutual tongue- and-groove structure. For instance, as shown in FIGS. 6A-6D, the interlocking part 910 can include a receiving groove portion, while the adjacent interlocking part 1010 can include a projecting tongue portion (or vice versa). The receiving groove portion of the interlocking part 910 can receive and secure the projecting tongue portion of the adjacent interlocking part 1010 when the slab 900 is brought into abutment with the adjacent slab 1000.

The design of the tongue-and-groove structure of the interlocking part 910 and adjacent interlocking part 1010 can vary. For instance, as in the example of FIGS. 6A-6D, the tongue-and-groove structure can be configured as a“click-fitting” system. Here, features of the interlocking part 910 and adjacent interlocking part 1010 can“click” into place and lock together, eliminating the need for adhesives such as glue, screws, nails, etc., and reducing the presence of gaps between the slabs 900 and 1000. The specific shape of the interlocking part 910 and adjacent interlocking part 1010 can vary, but can include, for instance, complementary hook-like shapes, as well as tapered outer edges allowing for the tongue portion to be pushed into and received by the groove portion.

Each slab 900 and 1000 can also include one or more additional interlocking part disposed along a length of another edge of the slab, as shown in FIGS. 6A-6D. Each additional interlocking part can be configured either in the same manner as the interlocking part 910, or in a manner opposite thereto. In the latter case, for example, if the interlocking part 910 includes a receiving groove portion, as shown in FIGS. 6A-6D, an additional interlocking part disposed on an opposite end of the slab 900 can instead include a projecting tongue portion.

The slab 900 can further include an indentation portion 920 formed into the upper surface of the slab 900 to mimic the appearance of a grout line extending along the joint between the slabs 900 and 1000, as explained in detail above. The indentation portion 920 can be disposed along the length of the edge of the slab 900, such that the indentation portion is positioned substantially above the interlocking part 910. Alternatively (or additionally), the adjacent slab 1000 can include an indentation portion formed into the upper surface of the slab 1000. Such indentation portion can be disposed along the length of the edge of the slab 1000, such that the indentation portion is positioned substantially above the interlocking part 1010

The shape of the indentation portion 920 can include an orthogonal inner portion 930 connecting to the upper surface of the slab 900, as shown in FIGS. 6A-6D. Here, the inner end of the indentation portion 920 can form an orthogonal or 90-degree angle extending to the upper surface of the slab 900, as explained in detail above. In another example, the indentation portion can include a rounded inner portion, as explained in detail above.

FIG. 7 is a flowchart illustrating a simplified, exemplary process for manufacturing a grout- free floor tile. The process 1100 can begin at step 1105 and proceed to step 1110, whereby as explained in detail herein, flooring tiles having the appearance of grouted joint lines can be manufactured.

At step 1110, a slab including a plurality of edges, an upper surface, and a lower surface can be provided. As explained above, the design of slabs 100 and 200 can vary. For example, the slabs 100 and 200 can be formed in any suitable shape, such as square or rectangle. The thickness‘C’ of each slab 100 and 200 (see FIG. 2) can be within any suitable range, such as a range of 8 mm to 30 mm, for example. The slabs 100 and 200 can be formed of any suitable material, such as ceramic, porcelain, travertine, slate, marble, granite, cement, vinyl, glass, wood, etc., or any combination thereof. In another example, slabs 100 and 200 can be formed of a composite material, such as stone plastic composite (SPC). The SPC can include a series of layers, such as a waterproof core, film and/or wear layers, a protective outer coating, and/or a foam underlayment, as is generally understood in the art.

At step 1115, a tile cutting machine, as is generally known in the art, can be utilized to process the slab a first time. Here, the tile cutting machine can firstly form an interlocking part along a length of an edge of the slab. As explained above, the interlocking part can be configured to interlock with an adjacent interlocking part disposed along a length of an edge of an adjacent slab. In this regard, the interlocking part can include a tongue- and-groove connecting structure. For example, the interlocking part can include one of a projecting tongue portion and a receiving groove portion, while the adjacent interlocking part can include the other of the projecting tongue portion and the receiving groove portion. The receiving groove portion can be formed to receive and secure the projecting tongue portion when the slab is brought into abutment with the adjacent slab.

At step 1120, the tile cutting machine can be utilized to process the slab a second time. Here, the tile cutting machine can secondly form an indentation portion formed into the upper surface of the slab along the length of the edge of the slab at a position substantially above the interlocking part. As explained above, the indentation portion can include either an orthogonal inner portion or a rounded inner portion. When the interlocking part interlocks with the adjacent interlocking part, the indentation portion can form a notch extending along a region (or joint) at which the slab abuts the adjacent slab.

The procedure 1100 illustratively ends at step 1125. The techniques by which the steps of procedure 1100 may be performed, as well as ancillary procedures and parameters, are described in detail above.

It should be noted that the steps shown in FIG. 7 are merely examples for illustration, and certain other steps may be included or excluded as desired. Further, while a particular order of the steps is shown, this ordering is merely illustrative, and any suitable arrangement of the steps may be utilized without departing from the scope of the embodiments herein. Even further, the illustrated steps may be modified in any suitable manner in accordance with the scope of the present claims.

Accordingly, the grout-free floor tile disclosed herein can include a notch that extends along a region at which the tile abuts an adjacent tile. The appearance of the notch can replicate the appearance of traditional grout used to fill a gap between the tiles, without the inconvenience of actually applying grout. The resulting floor tiles can be installed more easily and cost-effectively by eliminating the time and effort required for grouting, as well as the myriad of tools necessary for grouting. Also, due to the interlocking part formed into the edges of the tiles, adjacent tiles can interlock with each other in a structurally sound manner even without the presence of grout. The foregoing description has been directed to certain embodiments of the present disclosure. It will be apparent, however, that other variations and modifications may be made to the described embodiments, with the attainment of some or all of their advantages.

Accordingly, this description is to be taken only by way of example and not to otherwise limit the scope of the embodiments herein. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the embodiments herein.