U.S. patent application number 14/714320 was filed with the patent office on 2016-04-14 for linoleum based surface coverings with edge detail.
The applicant listed for this patent is ARMSTRONG WORLD INDUSTRIES, INC.. Invention is credited to Arne Berkemeier, Jens Ehlers, Marika Zobel.
Application Number | 20160102464 14/714320 |
Document ID | / |
Family ID | 53277095 |
Filed Date | 2016-04-14 |
United States Patent
Application |
20160102464 |
Kind Code |
A1 |
Ehlers; Jens ; et
al. |
April 14, 2016 |
LINOLEUM BASED SURFACE COVERINGS WITH EDGE DETAIL
Abstract
Described herein are surface coverings comprising: a linoleum
core; a first major surface terminating at a first edge, a second
major surface terminating at a second edge, and a peripheral edge
surface extending between the first and second edges; wherein the
peripheral edge surface is planar and oriented obliquely to the
first major surface and the second major surface. Methods of making
and using these surface coverings are also described.
Inventors: |
Ehlers; Jens; (Hamminkein,
DE) ; Berkemeier; Arne; (Diepholz, DE) ;
Zobel; Marika; (Hude, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ARMSTRONG WORLD INDUSTRIES, INC. |
Lancaster |
PA |
US |
|
|
Family ID: |
53277095 |
Appl. No.: |
14/714320 |
Filed: |
May 17, 2015 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62062528 |
Oct 10, 2014 |
|
|
|
Current U.S.
Class: |
428/44 ;
428/157 |
Current CPC
Class: |
E04F 2290/00 20130101;
E04F 15/02005 20130101; E04F 15/02033 20130101; E04F 15/102
20130101; E04F 15/16 20130101; D06N 1/00 20130101; E04F 2203/02
20130101; E04F 15/107 20130101 |
International
Class: |
E04F 15/02 20060101
E04F015/02; E04F 15/16 20060101 E04F015/16; E04F 15/10 20060101
E04F015/10 |
Claims
1. A surface covering comprising: a linoleum core; a first major
surface terminating at a first edge, a second major surface
terminating at a second edge, and a peripheral edge surface
extending between the first and second edges; the first major
surface being arranged parallel to the second major surface; the
first major surface defining a first surface area; the second major
surface defining a second surface area; and a carrier adjacent the
linoleum core; wherein the first surface area and the second
surface area are different.
2. The surface covering according to claim 1, wherein the
peripheral edge surface is planar and oriented obliquely to the top
major surface and the bottom major surface.
3. The surface covering according to claim 2, wherein the
peripheral edge surface is disposed at an angle from about 2
degrees to about 75 degrees with respect to a vertical reference
plane that intersects the top major surface.
4. The surface covering according to claim 3, wherein the angle is
from about 10 degrees to about 20 degrees.
5. The surface covering according to claim 1, wherein: the first
major surface is a top surface defining the first surface area and
the first edge; and the second major surface is a bottom surface
for placement on a support base, the bottom surface defining the
second surface area and the second edge; wherein the first surface
area is larger than the second surface area.
6. The surface covering according to claim 5, wherein the first
edge is spaced at a greater horizontal distance from a centerline
of the surface covering than the second edge.
7. The surface covering according to claim 1, wherein the
peripheral edge is sealed with a polyurethane sealant.
8. The surface covering according to claim 1, wherein the linoleum
core comprises a first linoleum layer and a second linoleum
layer.
9. The surface covering according to claim 1, further comprising a
coating disposed on the first major surface.
10. The surface covering according to claim 1, wherein the
peripheral edge surface is at an acute angle with the first major
surface and an obtuse angle with the second major surface.
11. The surface covering according to claim 1, wherein the surface
covering comprises a plurality of isotropic peripheral edge
surfaces each having a substantially identical edge profile in
cross sectional view.
12. A floor covering system comprising: a plurality of floor tiles
arranged edge-to-edge on a support base, each tile comprising: a
linoleum core comprising a first linoleum layer and a second
linoleum layer; a top major surface terminating at a top edge; a
bottom major surface terminating at a bottom edge; and a peripheral
edge surface extending between the top and bottom edges; and a
carrier; wherein the peripheral edge surface is planar and oriented
obliquely to the top and bottom major surfaces; and wherein a gap
formed between the peripheral edge surfaces of adjoining tiles, has
a greater width between the bottom edges of adjoining tiles than at
the top edges.
13. The flooring covering system according to claim 12, wherein the
gap has a substantially triangular cross section.
14. The floor covering system according to claim 13, wherein the
triangular cross section is in the form of an isosceles triangle
formed by the gaps of adjoining tiles.
15. The surface covering system according to claim 12, wherein the
peripheral edge surface is disposed at an angle from about 2
degrees to about 75 degrees with respect to a vertical reference
plane that intersects the top major surface.
16. The floor covering system according to claim 15, wherein the
angle is from about 10 degrees to about 20 degrees.
17. A floor tile comprising: a linoleum core comprising a first
linoleum layer and a second linoleum layer; a polymeric wear layer
disposed on the linoleum core; a carrier embedded in the first
linoleum layer; a top major surface terminating at a plurality of
top edges, a bottom major surface terminating at a plurality of
bottom edges, and a plurality of peripheral edge surfaces extending
between the top and bottom edges around a perimeter of the tile;
the top major surface being arranged parallel to the bottom major
surface; the wear layer defining the top major surface; the first
linoleum layer defining the bottom major surface; and wherein the
top major surface has a first area and the bottom major surface has
a second area, the second area being less than the first area.
18. The floor tile according to claim 17, wherein the peripheral
edge surfaces are each at an acute angle with the top major surface
and an obtuse angle with the bottom major surface.
19. The floor tile according to claim 17 or claim 18, wherein each
peripheral edge surface is disposed at an angle from about 10
degrees to about 20 degrees with respect to a vertical reference
plane oriented parallel to a centerline of the tile.
20. The floor tile according to claim 17, wherein the first
linoleum layer comprises a first linoleum composition and the
second linoleum layer comprises a second linoleum composition.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/062,528 filed on Oct. 10, 2014. The
disclosure of the above application is incorporated herein by
reference.
FIELD OF THE DISCLOSURE
[0002] The present invention relates to surface covering systems,
and more particularly to linoleum based floor tiles having edge
detail.
BACKGROUND
[0003] The ability of a floor covering product to remain
substantially flat under varying environment conditions is
desirable. Dimensional stability (DS) is one applicable measure of
floor covering products which may include linoleum panels or tiles.
In short, dimensional stability quantifies the characteristic of a
floor tile subjected to environmental changes in factors such as
ambient relative humidity to remain relatively true to its original
shape and dimensions. Excessive growth or shrinkage in dimension
may adversely cause curling or doming in individual tiles under low
or high relative humidity respectively. Curling or cupping causes
the edges of the tile to curl upwards with respect to the central
portion of the tile. Conversely, doming causes the portions of the
tile to bow or bubble upwards with respect to the edges. Industry
standards such as ASTM F2195-13 or others have been developed to
measure the dimensional stability of floor tiles and set applicable
performance levels.
[0004] In the production of linoleum floor tiles, continuous
formation processes are sometimes used. A relatively wide
continuous roll or sheet of linoleum is produced which moves
longitudinally along a transport system, typically comprising
calenders, rollers and/or conveyors, that defines a machine
direction ("MD"). Smaller individual tiles are then cut from the
larger material sheet by making cuts both along the machine
direction and across machine direction ("AMD"). The MD and AMD are
generally defined as being perpendicular to each other. The
dimensional stability (DS) varies in both the MD and AMD of the
floor product so that each is typically tested and measured
separately, with AMD DS typically having a higher value showing
poorer performance in that direction of the tile. Ideally, both MD
DS and AMD DS should be below the applicable maximums set by
industry standard and relatively close in value as possible which
is indicative of DS uniformity of the flooring product and
resistance to curling and doming.
[0005] Different edge details have sometimes been used for edges
cut in the machine direction versus those cut across machine
direction to mask dimensional stability differences between the MD
and AMD edges of the floor tiles.
[0006] Improvement in dimensional stability of flooring products is
desirable.
SUMMARY
[0007] In some embodiments, the present invention provides a floor
tile with improved dimensional stability that overcomes the
foregoing design limitations. In certain embodiments, the floor
tile comprises linoleum. In some embodiments, the floor tiles may
have isotropic edges (i.e. the cross sectional edge profile is
identical on all sides). This eliminates a need to use differential
MD and AMD edge details for masking dimensional stability
differences in the MD versus AMD directions. Accordingly, special
tile fabrication techniques previously used to mask dimensional
stability differences are no longer required.
[0008] Advantageously, the present invention allows unidirectional
installation of tiles in the flooring system so that MD edges may
be directly abutted against MD edges, and AMD edges may be directly
abutted against AMD edges without detriment. In addition, the
present invention permits the manufacture and installation of
non-square tiles (e.g. rectangular and plank shapes) to form a
variety of aesthetic visual patterns because like MD-MD edges
and/or like AMD-AMD edges may be in direct contact without
adversely affecting dimensional stability. Heretofore, such tile
shapes were generally unobtainable. Some embodiments of the present
invention allow a wide variety of floor patterns to be formed using
non-square tiles, such as without limitation a herringbone, a
subway or running bond tile layout (i.e. longitudinally offset
joints between adjoining rows of tiles), etc. Accordingly, tile
installation techniques and patterns are not strictly limited to
square grid patterns of the past.
[0009] In some embodiments, the present invention provides a
surface covering comprising a linoleum core, a first major surface
terminating at a first edge, a second major surface terminating at
a second edge, and a peripheral edge surface extending between the
first and second edges. The peripheral edge surface is planar and
oriented obliquely to the first major surface and the second major
surface. In certain embodiments, the peripheral edge surface is at
an acute angle with the first major surface and an obtuse angle
with the second major surface.
[0010] In some embodiments, the surface coverings of the present
invention comprise a linoleum core. In some embodiments, the
linoleum core comprises a plurality of layers. In some embodiments,
the linoleum core comprises a first linoleum layer and a second
linoleum layer. In some embodiments, the first linoleum layer
comprises a first linoleum composition. In some embodiments, the
second linoleum layer comprises a second linoleum composition. In
some embodiments, the first linoleum layer comprises a first
linoleum composition and the second linoleum layer comprises a
second linoleum composition.
[0011] In some embodiments, the present invention provides a
surface covering comprising a linoleum core, a first major surface
terminating at a first edge, a second major surface terminating at
a second edge, and a peripheral edge surface extending between the
first and second edges, the first major surface being arranged
parallel to the second major surface, the first major surface
defining a first surface area, the second major surface defining a
second surface area, and a carrier. In some embodiments, the
carrier is embedded, at least partially, in the linoleum core. In
some embodiments, the first surface area and the second surface
area are different.
[0012] In some embodiments, the present invention provides a floor
covering system comprising a plurality of floor tiles arranged
edge-to-edge on a support base, each tile comprising a linoleum
core, a top major surface terminating at a top edge, a bottom major
surface terminating at a bottom edge, and a peripheral edge surface
extending between the top and bottom edges, and a carrier. In some
embodiments, the carrier is embedded, at least partially, in the
linoleum core. The peripheral edge surface is planar and oriented
obliquely to the top and bottom major surfaces. A gap is formed
between adjoining tiles between the peripheral edge surfaces of the
tiles, the gap having a greater width between the bottom edges of
adjoining tiles at the support base than at the top edges.
[0013] In some embodiments, the present invention provides a floor
tile comprising: a carrier; a linoleum core; a polymeric wear layer
disposed on the linoleum core; a top major surface terminating at a
plurality of top edges, a bottom major surface terminating at a
plurality of bottom edges, and a plurality of peripheral edge
surfaces extending between the top and bottom edges around a
perimeter of the tile; the top major surface being arranged
parallel to the bottom major surface; the wear layer defining the
top major surface; wherein the top major surface has a first area
and the bottom major surface has a second area, the second area
being less than the first area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The features of the exemplary embodiments of the present
invention will be described with reference to the following
drawings, where like elements are labeled similarly, and in
which:
[0015] FIG. 1 is a top plan view of a prior art quarter turned
flooring system;
[0016] FIG. 2 is a side elevation cross-sectional view of a floor
tile for use in a flooring system according to the present
disclosure;
[0017] FIG. 3 is an exploded view of the floor tile of FIG. 2;
[0018] FIG. 4 is a top plan view of an exemplary floor tile of the
present invention having a square configuration and showing the
fabrication process material flow, or machine direction;
[0019] FIG. 5 is a top plan view of an exemplary floor tile of the
present invention having a non-square configuration and showing the
fabrication process material flow, or machine direction;
[0020] FIG. 6 is a top plan view of an exemplary carrier of the
present invention;
[0021] FIG. 7 is an exemplary flooring system with a pattern formed
by using exemplary square tiles of the present invention; and
[0022] FIG. 8 is a side view of two adjoining abutting floor tiles
placed on a common support base.
[0023] All drawings are schematic and not necessarily to scale.
Parts given a reference numerical designation in one figure may be
considered to be the same parts where they appear in other figures
without a numerical designation for brevity unless specifically
labeled with a different part number and described herein.
DETAILED DESCRIPTION
[0024] The features and benefits of the invention are illustrated
and described herein by reference to non-limiting exemplary
embodiments. This description of exemplary embodiments is intended
to be read in connection with the accompanying drawings, which are
to be considered part of the entire written description.
Accordingly, the disclosure expressly should not be limited to such
exemplary embodiments illustrating some possible non-limiting
combination of features that may exist alone or in other
combinations of features.
[0025] In the description of embodiments disclosed herein, any
reference to direction or orientation is merely intended for
convenience of description and is not intended in any way to limit
the scope of the present invention. Relative terms such as "lower,"
"upper," "horizontal," "vertical,", "above," "below," "up," "down,"
"top" and "bottom" as well as derivative thereof (e.g.,
"horizontally," "downwardly," "upwardly," etc.) should be construed
to refer to the orientation as then described or as shown in the
drawing under discussion. These relative terms are for convenience
of description only and do not require that the apparatus be
constructed or operated in a particular orientation. Terms such as
"attached," "affixed," "connected," "coupled," "interconnected,"
and similar refer to a relationship wherein structures are secured
or attached to one another either directly or indirectly through
intervening structures, as well as both movable or rigid
attachments or relationships, unless expressly described
otherwise.
[0026] FIGS. 2-5 depict non-limiting exemplary embodiments of a
surface covering such as without limitation a floor tile 100 in
accordance with principles of the present invention. Floor tile 100
may be used for forming a flooring system comprised of a plurality
of tiles laid with abutting joints between tiles. In some
embodiments, the floor tile 100 may be a linoleum tile. The terms
"flooring tile" and "product" is used herein for convenience of
description only, such flooring products may be applied to any
suitable type and oriented surface including without limitation
horizontal, vertical, and/or angled or sloped surfaces. Application
surfaces or substrates to which the flooring product is mounted may
include floors, walls, countertops, ceilings, and others.
Accordingly, the invention and non-limiting embodiments of the
flooring products described herein are not limited in their
application or use strictly to flooring systems alone.
[0027] In some embodiments, the surface coverings of the present
invention comprise a linoleum core. In some embodiments, the
linoleum core comprises a plurality of layers. In some embodiments,
the linoleum core comprises a first linoleum layer and a second
linoleum layer. In some embodiments, the first linoleum layer
comprises a first linoleum composition. In some embodiments, the
second linoleum layer comprises a second linoleum composition. In
some embodiments, the first linoleum layer comprises a first
linoleum composition and the second linoleum layer comprises a
second linoleum composition.
[0028] In some embodiments, for example those described in FIGS.
2-5, floor tile 100 may comprise (from the bottom upwards) a
carrier 110, a linoleum core 150, the linoleum core 150 comprising
a first (or bottom) linoleum layer 120 disposed on the carrier, a
second (or top) linoleum layer 130 disposed on the first linoleum
layer, and a coating 140 disposed thereon. In some embodiments, a
single homogenous linoleum core 151 may be provided in lieu of a
composite structure having a plurality of linoleum layers.
[0029] In some embodiments, the second linoleum layer may be a
visual linoleum layer in which various decorative additives may be
incorporated to create the visual. In some embodiments, wherein the
carrier is embedded in the first linoleum layer, the first linoleum
layer may form the bottom major surface, which may be placed
adjacent a suitable support base or underlayment. In the case of a
flooring system, the support base may be a subfloor.
[0030] In some embodiments, tile 100 further includes a top major
surface 101, an opposing bottom major surface 102, and peripheral
edge surfaces 103 extending between the top and bottom major
surfaces around the perimeter of tile 100. The top and bottom
extremities of peripheral edge surfaces 103 define top and bottom
edges 104 and 105, respectively which similarly extend around the
entire perimeter of tile 100. Top and bottom edges 104, 105 and
peripheral edge surfaces 103 collectively define two pairs of
opposing parallel MD and AMD edges for each tile 100 that extend
between the top and bottom major surfaces 101, 102. In some
embodiments, tile 100 further comprises a length L and width W
measured in the horizontal plane along the top and bottom major
surfaces 101, 102. In various embodiments, length L and width W may
be substantially equal or different.
[0031] Any suitable thickness of linoleum floor tile 100 may be
used. Some embodiments provide that the overall thickness of the
floor tile 100 may be varied, e.g. 2 mm being used for lighter wear
applications and greater thicknesses such as 2.5 mm and 3.2 mm
being used for more critical applications. However, in general,
some embodiments provide that the tile 100 can have an overall
thickness of from 1 mm to 6 mm; alternatively from 1.5 mm to 4
mm.
[0032] In some embodiments, the first linoleum composition
comprises: linoleum cement, a first organic filler, and a first
inorganic filler. In some embodiments, the second linoleum
composition comprises: linoleum cement, a second organic filler,
and a second inorganic filler. According to some embodiments, the
second linoleum composition may have relatively lower
concentrations of linoleum cement and relatively higher
concentrations of organic filler than the first linoleum
composition. In some embodiments, the enhanced dimensional
stability is the result of reduced sensitivity to changes in
moisture. In other words, as relative humidity of the surrounding
environment increases or decreases, the linoleum core is less
likely to "dome" at high humidity and "curl" at low humidity.
[0033] In some embodiments, the first linoleum composition
comprises from about 30 wt. % to about 45 wt. % of linoleum cement,
based on the total weight of the first linoleum composition. In
some embodiments, the first linoleum composition comprises about 41
wt. % of linoleum cement, based on the total weight of the first
linoleum composition.
[0034] In some embodiments, the first linoleum composition
comprises from about 18 wt. % to about 42 wt. %, preferably from
about 20 wt. % to about 30 wt. % of a first inorganic filler, based
on the total weight of the first linoleum composition. Some
embodiments provide that the first inorganic filler comprises
particles having an average particle size of from about 0.5 .mu.m
to about 20 .mu.m. Some embodiments provide that the first
inorganic filler comprises particles having an average particle
size of from about 1 .mu.m to about 10 .mu.m. Some embodiments
provide that the first inorganic filler comprises particles having
an average particle size of from about 1 .mu.m to about 5
.mu.m.
[0035] Some embodiments provide that the first inorganic filler may
comprise limestone powder (calcium carbonate powder), chalk powder,
kaolin clay, silica, vermiculite, ball clay or bentonite, talc,
mica, gypsum, perlite, titanium dioxide, sand, barium sulfate,
dolomite, wollastonite, calcite, pigments, zinc oxide, zinc
sulfate, or a combination of two or more thereof.
[0036] In some embodiments, the first linoleum composition
comprises from about 7 wt. % to about 30 wt. %, preferably from
about 15 wt. % to about 30 wt. % of a first organic filler, based
on the total weight of the first linoleum composition. In some
embodiments, the first linoleum composition comprises from about 18
wt. % to about 23 wt. % of the first organic filler, based on the
total weight of the first linoleum composition.
[0037] Some embodiments provide that the first and/or second
organic filler comprises a cellulosic, a polymeric material, a
non-polymeric material, or a combination of two or more thereof. In
some embodiments, the first and/or second organic filler may be a
fibrous material or a particulate material. In some embodiments,
the first and/or second organic filler comprises a cellulosic
material selected from wood fibers, cork, wood shavings, wood
flour, paper fibers, cotton linters, a combination of two or more
thereof.
[0038] In some embodiments the wood flour may be made from a
hardwood or a softwood. In some embodiments, the wood flour
comprises particles having a particle size distribution as follows:
<160 .mu.m: 40-90%, and <80 .mu.m 10-50%. In other
embodiments, the wood flour comprises particles having a particle
size distribution as follows: <160 .mu.m 50-85%; and <80
.mu.m 10-30%.
[0039] The polymeric material may include polyolefin, and the
non-polymeric material may include a hydrophobic material. In some
embodiments, the hydrophobic material has a melting point below
100.degree. C. In some embodiments, the non-polymeric material is
selected from Montan wax; Carnauba wax; bee wax; paraffin; and a
combination of two or more thereof.
[0040] In some embodiments, the non-polymeric material may be
present in an amount ranging from about 0.1 wt. % to about 1 wt. %
based on the total weight of the first linoleum composition. In
some embodiments, the non-polymeric material may be present in an
amount ranging from about 0.1 wt. % to about 0.6 wt. % based on the
total weight of the first linoleum composition.
[0041] In some embodiments, the thickness of the first linoleum
layer 120 may be varied and range from about 0.5 mm to about 5 mm;
alternatively from about 0.75 mm to about 3 mm; alternatively from
about 0.9 mm to about 1.1 mm.
[0042] In some embodiments, the second linoleum composition
comprises: from about 17.5 wt. % to about 70 wt. % of linoleum
cement, based on the total weight of the second linoleum
composition. In some embodiments, the second linoleum composition
comprises from about 25 wt. % to about 45 wt. % of linoleum cement,
based on the total weight of the second linoleum composition. In
some embodiments, the second linoleum composition comprises from
about 30 wt. % to about 40 wt. % of linoleum cement, based on the
total weight of the second linoleum composition. In some
embodiments, the second linoleum composition comprises about 36 wt.
% of linoleum cement, based on the total weight of the second
linoleum composition.
[0043] In some embodiments, the second linoleum composition
comprises from about 10 wt. % to about 20 wt. % of the second
inorganic filler, based on the total weight of the second linoleum
composition. In some embodiments, the second linoleum composition
comprises from about 12 wt. % to about 18 wt. % of the second
inorganic filler, based on the total weight of the second linoleum
composition. In some embodiments, the second linoleum composition
comprises about 14 wt. % of the second inorganic filler, based on
the total weight of the second linoleum composition.
[0044] Some embodiments provide that the second inorganic filler
may include limestone powder (calcium carbonate powder), chalk
powder, kaolin clay, silica, vermiculite, ball clay or bentonite,
talc, mica, gypsum, perlite, titanium dioxide, sand, barium
sulfate, dolomite, wollastonite, calcite, pigments, zinc oxide, and
zinc sulfate, or a combination of two or more thereof.
[0045] Some embodiments provide that the second linoleum
composition comprises a second organic filler. In some embodiments,
the second linoleum composition comprises from about 30 wt. % to
about 45 wt. % of a second organic filler, based on the total
weight of the second linoleum composition. In some embodiments, the
second linoleum composition comprises from about 36 wt. % to about
41 wt. % of the second organic filler, based on the total weight of
the second linoleum composition. In some embodiments, the second
linoleum composition comprises about 39 wt. % of the second organic
filler, based on the total weight of the second linoleum
composition.
[0046] In some embodiments, the thickness of the second linoleum
layer 130 may be varied and range from about 0.5 mm to about 5 mm;
alternatively from about 0.75 mm to about 3 mm; alternatively from
about 1.1 mm to about 1.4 mm. In certain embodiments, the thickness
of the second linoleum layer 130 may be greater than the thickness
of the first linoleum layer 120.
[0047] In some embodiments, such as described in FIGS. 2 and 3, the
surface covering may further comprise a coating 140. In some
embodiments, coating 140 may perform as a wear layer. In some
embodiments, coating 140 is applied to the second linoleum
composition. In some embodiments, coating 140 is UV curable,
moisture curable or thermally curable. In some embodiments, coating
140 may be transparent and cured by UV radiation. In some
embodiments, coating 140 provides good scratch and abrasion
resistance and is sufficiently transparent to allow a print design
to be visible from and through the topside of the product. In some
embodiments, coating 140 comprises a UV curable polyurethane. In
some embodiments, coating 140 comprises a moisture curable
polyurethane. In some embodiments, coating 140 comprises an
acrylate. In some embodiments, coating 140 comprises a polyurethane
and an acrylate.
[0048] In some embodiments, coating 140 may comprise particles that
enhance dimensional stability and/or scratch resistance. In some
embodiments, the particles are selected from chalk, barium sulfate,
slate powder, silica, kaolin, quartz powder, talc, lignin, powdered
glass, aluminum oxide, and glass fibers.
[0049] In some embodiments, coating 140 may have a thickness that
ranges from about 0.001 to 0.1 mm. In some embodiments coating 140
may have a thickness that ranges from about 0.01 to 0.07 mm. In
some embodiments coating 140 may have a thickness that ranges from
about 0.015 to 0.05 mm.
[0050] In some embodiments, carrier 110 enhances the mechanical
integrity of the floor tile 100 by acting as a backbone to the
overall surface covering. In some embodiments, carrier 110 may be
partially or completely embedded in the first linoleum layer 120
near the bottom surface 102 of the linoleum core. Embedding the
carrier 110 in the first linoleum layer 120 may contribute to
improving the dimensional stability of the floor tile 100 in some
embodiments.
[0051] In some embodiments, carrier 110 may include a binder and a
fibrous material. In some embodiments, the fibrous material is
woven or knitted. In some embodiments, the binder may be present in
an amount ranging from about 0 wt. % to about 40 wt. %, based on
the weight of carrier 110. In other embodiments, the binder may be
present in an amount ranging from about 1 wt. % to about 30 wt. %
based on the weight of carrier 110.
[0052] According to some embodiments, the fibrous material may be
selected from a synthetic fiber, a cellulosic fiber, a natural
fiber, a synthetic fabric, and a combination of two or more
thereof.
[0053] In some embodiments, the synthetic fiber may be selected
from a polyester (e.g. polyethylene terepthalate), a polyolefin
(e.g. polypropylene), polytetrafluoroethylene, polyacrlyonitrile, a
polyamide (e.g. nylon), polyacrylate, fiberglass, etc., and a
combination of two or more thereof. In some embodiments, the
cellulosic fiber and natural fiber may be selected from cotton,
jute, viscose, kraft paper, rayon, sisal, and a combination of two
or more thereof. Some embodiments provide that the carrier may
comprise a material selected from: jute fabric; a mixed fabric of
natural fibers; carbon fibers; aramid fibers; quartz fibers;
alumina fibers; silicon carbide fibers; and a combination of two or
more thereof.
[0054] In some embodiments, the carrier comprises polyethylene
terephthalate. In some embodiments, the carrier comprises
polyethylene terephthalate and fiberglass.
[0055] In some embodiments, the binder may comprise a thermoplastic
resin or a thermoset resin that is selected from, epoxies,
polyurethanes, acrylic latex, phenolic resin, polyvinyl alcohol,
carbohydrate polymers (i.e. starch), a cellulosic resin, a
polyacrylamide, urea-formaldehyde, a melamine resin (e.g.
melamine-formaldehyde, melamine-phenol-formaldehyde copolymer), an
acrylic copolymer, styrene butadiene rubber, and a combination of
two or more thereof. In some embodiments the binders may include
one or more resins derived from the following monomers vinyl
acetate, vinyl propionate, vinyl butyrate, vinyl chloride,
vinylidine chloride, vinyl fluoride, vinylidene fluoride, ethyl
acrylate, methyl acrylate, propyl acrylate, butyl acrylate, ethyl
methacrylate, methyl methacrylate, butyl methacrylate, hydroxyethyl
methylacrylate, styrene, butadiene, urethane, epoxy, melamine, and
an ester.
[0056] In some embodiments, the peripheral edge surfaces 103 may be
undercut and disposed at an inward angle A1 measured from the top
edge 104 between 0 and 90 degrees to a vertical reference plane
intersecting top edge 104 and extending perpendicular to the top
and bottom major surfaces 101, 102, as shown in FIG. 2. The
vertical reference plane is parallel to centerline CL of the floor
tile 100. Peripheral edge surfaces 103 may be planar and form an
acute angle A2 with respect to the top major surface 101 and an
obtuse angle A3 with respect to the bottom major surface 102. Each
peripheral edge surface 103 is therefore oblique to the top and
bottom major surfaces of floor tile 100.
[0057] In some embodiments, angle A1 may be from about 2 degrees to
about 75 degrees, alternatively from about 5 degrees to about 45
degrees, and alternatively in certain embodiments from about 10
degrees to about 20 degrees. The undercut profile forms a top major
surface 101 which is greater in width W and length L (measured
between the top peripheral edges 104 along the horizontal plane
defined by the top major surface) than the width W and length L of
the bottom major surface 102 (measured between bottom peripheral
edges 105 along the horizontal plane defined by the bottom major
surface). Accordingly, the peripheral edge surfaces 103 slope
inwards towards the centerline CL of the tile going from the top
major surface 101 of the tile 100 to the bottom major surface 102
such that the bottom edge 105 is inwardly offset from the top edge
104 with respect to centerline CL of the tile.
[0058] With continuing reference to FIG. 2, the perimeter gap 106
may have a substantially triangular shape in cross section with
base of the triangle being formed by the support base or
underlayment (e.g. subfloor) on which the floor tile 100 is placed.
The gap 106 is therefore widest adjacent the bottom edge 105 of the
tile 100 at the base-to-tile interface than at the top edge 104
which forms an upper apex of the gap. When two tiles 100 are placed
in edge-to-edge abutting contact, the triangular cross section
formed by the mating gaps 106 of each tile form an isosceles
triangle in cases where each tile has a substantially similar
peripheral edge surface 103 profile (allowing for tolerances in
cutting or filing the tile edges to shape).
[0059] In some embodiments, all peripheral edge surfaces 103 may be
angled so that the tile 100 has an undercut edge profile on all
four MD and AMD edges. In some embodiments, the angles A1 may be
identical on all four sides providing four isotropic tile edges in
cross sectional profile. In other embodiments, the angles A1 may be
different. In certain embodiments, the angles A1 may be identical
on the opposing MD sides of the tile and the angles A1 may be
identical on the AMD sides of the tile but different than the MD
side angle. Numerous variations are possible.
[0060] In some embodiments, the peripheral edge surfaces 103 of
tile 100 are sealed to minimize moisture absorption by the tile,
which might cause distortion and contribute to curling or doming.
In some embodiments, a polymeric seal coat or sealant such as
without limitation polyurethane may be applied to the cut tile MD
and AMD peripheral edge surfaces 103 to serve as moisture barrier.
Other suitable polymeric coatings may be used for this purpose.
[0061] According to another aspect of the invention, unidirectional
tile layout may be produced using non-square tiles. In some
embodiments, using rectangular or plank-shaped tiles, machine
direction (MD) peripheral edge surfaces are directly abutted
against across machine direction (AMD) peripheral edge surfaces.
Significantly, MD edges of two adjoining tiles may be directly
abutted. Advantageously, this allows creation of a wide variety of
possible floor patterns not heretofore achievable with linoleum
tiles that could only be laid with AMD-MD edge contact for masking
dimensional stability differences. In addition, a combination of
non-square tiles (e.g. rectangular) may be mixed with square tiles
in a single flooring system without regard for which peripheral
edge surfaces (MD or AMD) abut each other in the layout. This is
possible due to the improvement in dimensional stability
attributable to isotropic peripheral edge surface profiles, angled
peripheral edge surface profiles, and/or tile size.
[0062] As shown in FIG. 7, a unidirectional tile layout may also be
produced using square tiles 100 in which MD edges can directly
contact MD edges of adjoining tiles, or AMD edges can directly
contact AMD edges of adjoining tiles without concern. This is
attributable, at least in part, to the tiles 100 according to the
present disclosure having isotropic edge profiles. The directional
arrows show the MD and AMD direction and illustrate the tile
orientation and layout possible. In the layout shown, a combination
of AMD-MD edge contact and AMD-AMD/MD-MD edge contact is possible
(emphasized by dashed arrows in which an AMD edge of one tile abuts
an AMD edge of another and MD edge of one tile abuts MD edge of
another). The direction of the tiles 100 laid may therefore be
random.
[0063] An exemplary method for installing floor tiles according to
the present invention may include providing a plurality of floor
tiles 100. In some embodiments, the floor tiles comprise linoleum.
Floor tiles 100 each include an opposing pair of peripheral edge
surfaces extending parallel to the machine direction (e.g. MD
edges) and an opposing pair of peripheral edge surfaces extending
parallel to the across machine direction (e.g. AMD edges).
[0064] The method continues with placing a first floor tile 100 on
a support base that supports the tile and may be at any orientation
including horizontal, vertical, and/or angled. A second floor tile
100 is then placed on the support base. An MD edge of the second
floor tile is then abutted against an AMD edge of the first floor
tile. A third floor tile 100 may then be placed on the support
base. An MD edge of the third floor tile is then abutted against an
AMD edge of the second floor tile.
[0065] Because the tiles 100 have isotropic edges, like MD edges
and like AMD edges may alternatively be abutted against each other.
Accordingly, in certain embodiments and variations of the method,
an AMD edge of the second floor tile 100 may be abutted against an
AMD edge of the first floor tile 100 (see, e.g. FIG. 7 showing tile
with dashed arrow in which an AMD edge of one abuts an AMD edge of
another). A MD edge of the third floor tile 100 may be abutted
against a MD edge of the second floor tile, or optionally an AMD
edge of the third floor tile may be abutted against the MD edge of
the second floor tile.
[0066] It will be appreciated that the foregoing method may be used
with square or non-square tiles, and combinations thereof.
[0067] Advantageously, floor tile 100 and corresponding flooring
systems described herein remove the restrictions for installing
floors and shapes of tile which can be utilized.
[0068] The invention will be described in greater detail by way of
a specific example. The following example is offered for
illustrative purposes and is not intended to limit the invention in
any manner.
Example
[0069] Dimensional stability tests are conducted to compare 48 cm
(18 inch) square tiles versus 30.5 cm (12 inch) square tiles, the
results of which are shown below in Table 1.
TABLE-US-00001 TABLE 1 Tile Size (cm) MD DS (%) AMD DS (%) 48 0.03
0.09 48 0.03 0.09 48 0.04 0.10 48 0.04 0.07 30.5 0.08 0.13 30.5
0.08 0.15 30.5 0.08 0.15 30.5 0.08 0.15 30.5 0.09 0.16 30.5 0.08
0.13
[0070] As described in Table 1 (above), 48 cm (18 inch) square
tiles unexpectedly provide greater AMD dimensional stability than
30.5 cm (12 inch) square tiles.
[0071] While the foregoing description and drawings represent
exemplary embodiments of the present disclosure, it will be
understood that various additions, modifications and substitutions
may be made therein without departing from the spirit and scope and
range of equivalents of the accompanying claims. In particular, it
will be clear to those skilled in the art that the present
invention may be embodied in other forms, structures, arrangements,
proportions, sizes, and with other elements, materials, and
components, without departing from the spirit or essential
characteristics thereof. In addition, numerous variations in the
methods/processes described herein may be made within the scope of
the present disclosure. One skilled in the art will further
appreciate that the embodiments may be used with many modifications
of structure, arrangement, proportions, sizes, materials, and
components and otherwise, used in the practice of the disclosure,
which are particularly adapted to specific environments and
operative requirements without departing from the principles
described herein. The presently disclosed embodiments are therefore
to be considered in all respects as illustrative and not
restrictive. The appended claims should be construed broadly, to
include other variants and embodiments of the disclosure, which may
be made by those skilled in the art without departing from the
scope and range of equivalents.
* * * * *