U.S. patent application number 14/714322 was filed with the patent office on 2016-04-14 for linoleum based flooring 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 | 20160102465 14/714322 |
Document ID | / |
Family ID | 55655075 |
Filed Date | 2016-04-14 |
United States Patent
Application |
20160102465 |
Kind Code |
A1 |
Ehlers; Jens ; et
al. |
April 14, 2016 |
LINOLEUM BASED FLOORING WITH EDGE DETAIL
Abstract
Described herein are surface coverings comprising: a linoleum
core; a top major surface having a first length and a first width,
the top major surface terminating at a first edge; a bottom major
surface having a second length and a second width, the bottom major
surface terminating at a second edge; and a peripheral edge surface
extending between the first and second edges, the peripheral edge
surface being planar and oriented obliquely to the top and bottom
major surfaces; wherein at least one of the first length or first
width is smaller than the second length or second width
respectively. 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: |
55655075 |
Appl. No.: |
14/714322 |
Filed: |
May 17, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62062528 |
Oct 10, 2014 |
|
|
|
Current U.S.
Class: |
428/44 ;
428/157 |
Current CPC
Class: |
D06N 1/00 20130101; E04F
15/107 20130101; E04F 15/16 20130101; E04F 15/105 20130101; E04F
15/02033 20130101 |
International
Class: |
E04F 15/02 20060101
E04F015/02; E04F 15/10 20060101 E04F015/10; D06N 1/00 20060101
D06N001/00; E04F 15/16 20060101 E04F015/16 |
Claims
1. A surface covering comprising: a linoleum core; a top major
surface having a first length and a first width, the top major
surface terminating at a first edge; a bottom major surface having
a second length and a second width, the bottom major surface
terminating at a second edge; and a peripheral edge surface
extending between the first and second edges, the peripheral edge
surface being planar and oriented obliquely to the top and bottom
major surfaces; wherein at least one of the first length or first
width is smaller than the second length or second width
respectively.
2. The surface covering according to claim 1, wherein the top major
surface has a smaller surface area than the bottom major
surface.
3. The surface covering according to claim 1, wherein the
peripheral edge surface is disposed at an angle from about 5
degrees to about 30 degrees with respect to a vertical reference
plane that intersects the second edge of the linoleum core.
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 linoleum
core comprises a first linoleum layer and a second linoleum
layer.
6. The surface covering according to claim 5, further comprising a
coating disposed on the second linoleum layer.
7. The surface covering of claim 1, wherein the peripheral edge
surface is sealed with a sealant.
8. 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.
9. The surface covering according to claim 1, wherein the top major
surface terminates at a top edge and the bottom major surface
terminates at a bottom edge, and the peripheral edge surface
extends between the top and bottom edges.
10. The surface covering according to claim 9, wherein the bottom
edge is spaced at a greater horizontal distance from a centerline
of the surface covering than the top edge.
11. The surface covering according to claim 1, wherein the top
major surface is arranged parallel to the bottom major surface.
12. The surface covering according to claim 1, wherein the top
major surface defines a first surface area and the bottom major
surface defines a second surface area, and wherein the second
surface area is greater than the first surface area.
13. 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 embedded at least partially in the first linoleum layer;
wherein the peripheral edge surface is planar and oriented
obliquely to the top and bottom major surfaces; a gap formed
between adjacent tiles between the peripheral edge surfaces of the
tiles, the gap having a greater width between the top edges of
adjacent tiles than at the bottom edges.
14. The flooring covering system according to claim 13, wherein the
gap has a substantially triangular cross section.
15. The floor covering system according to claim 14, wherein the
triangular cross section is in the form of an isosceles triangle
formed by the gaps of adjacent tiles.
16. The floor covering system according to claim 13, wherein the
peripheral edge surface is disposed at an angle from about 5
degrees to about 30 degrees with respect to a vertical reference
plane that intersects the first edge of the linoleum core.
17. The floor covering system according to claim 16, wherein the
angle is from about 10 degrees to about 20 degrees.
18. A floor tile comprising: a linoleum core comprising a first
linoleum layer and a second linoleum layer; a carrier embedded at
least partially in the first linoleum layer; a polymeric wear layer
disposed on the second 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; wherein the top major surface has a first
area and the bottom major surface has a second area, the second
area being larger than the first area.
19. The floor tile according to claim 18, wherein the peripheral
edge surfaces are each at an obtuse angle with the top major
surface and an acute angle with the bottom major surface.
20. The floor tile according to claim 19, 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.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/062,536 filed on Oct. 10, 2014. The
disclosure of the above application is incorporated herein by
reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to surface coverings, 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 environmental conditions is
desirable. Dimensional stability (DS) is one applicable measure of
floor coverings 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. To compensate for these
differences in dimensional stability, every other tile is rotated
90 degrees ("quarter turning") during installation (see, e.g. FIG.
1) so that no MD edge (i.e. edges parallel to the machine
direction) directly contacts an AMD edge (i.e. edges parallel to
the across machine direction) of an adjacent tile.
[0006] The foregoing quarter turn installation method does not
allow for unidirectional installation where like MD and AMD edges
can be disposed and directly abutted against each other.
Accordingly, only square tiles can generally be used so every MD
edge contacts an AMD edge after quarter turning so no like edge
details meet in the installed floor. Unfortunately, this severely
limits the patterns which may be created with linoleum tiles.
[0007] Embodiments of the present invention are designed to
overcome the aforementioned issues.
SUMMARY
[0008] 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 tile may
comprise isotropic edges (i.e. 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.
[0009] Advantageously, the present invention allows unidirectional
installation of tiles so that MD edges may be directly abutted
against MD edges, and AMD edges may be directly abutted against AMD
edges without detriment. Quarter turning tiles for installation is
therefore not required. 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 patterns because
like MD-MD edges and/or like AMD-AMD edges may be in direct contact
without adversely affecting dimensional stability. Heretofore, tile
shapes in which MD and AMD edges must be directly abutted to each
other in the floor layout were unobtainable. Tiles according to the
present disclosure therefore 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.
[0010] In some embodiments, a surface covering includes: a linoleum
core; a top major surface having a first length and a first width,
the top major surface terminating at a first edge; a bottom major
surface having a second length and a second width, the bottom major
surface terminating at a second edge; and a peripheral edge surface
extending between the first and second edges, the peripheral edge
surface being planar and oriented obliquely to the top and bottom
major surfaces; wherein at least one of the first length or first
width is less than the second length or second width
respectively.
[0011] 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.
[0012] In other embodiments, a surface covering includes: 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; the top
major surface being arranged parallel to the bottom major surface;
the top major surface defining a first surface area; the bottom
major surface defining a second surface area; and a carrier,
wherein the second surface area is greater than the first surface
area. In some embodiments, the carrier is embedded at least
partially in the linoleum core.
[0013] Further embodiments provide 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; wherein
the peripheral edge surface is planar and oriented obliquely to the
top and bottom major surfaces. In some embodiments, a gap is formed
between adjoining tiles between the peripheral edge surfaces of the
tiles, the gap having a greater width between the top edges of
adjoining tiles than at the bottom edges.
[0014] Still further embodiments provide a floor tile comprising: a
linoleum core; a 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; and a carrier.
[0015] In some embodiments, wherein the linoleum core comprises a
first linoleum layer and a second linoleum layer, the carrier is
embedded, at least partially in the first linoleum layer.
[0016] In some embodiments, the carrier is completely embedded in
the first linoleum layer. In those embodiments wherein the carrier
is completely embedded in the first linoleum layer, the first
linoleum layer defines the bottom major surface. In some
embodiments, the top major surface has a first area and the bottom
major surface has a second area, the second area being greater than
the first area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] 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:
[0018] FIG. 1 is a top plan view of a prior art quarter turned
flooring system;
[0019] FIG. 2 is a side elevation cross-sectional view of a floor
tile for use in a flooring system according to the present
disclosure;
[0020] FIG. 3 is an exploded view thereof;
[0021] 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;
[0022] 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;
[0023] FIG. 6 is a top plan view of an exemplary carrier of the
present invention;
[0024] FIG. 7 is an exemplary flooring system with a pattern formed
by using exemplary square tiles of the present invention; and
[0025] FIG. 8 is a side view of two adjoining abutting floor tiles
of the preset invention placed on a common support base.
[0026] 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
[0027] 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.
[0028] 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.
[0029] 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.
[0030] FIGS. 2-5 depict non-limiting exemplary embodiments of a
surface covering product such as without limitation a floor tile
100 in accordance with principles of the present invention. Floor
tiles 100 may be used for forming a flooring system comprised of a
plurality of tiles laid with abutting joints between tiles. In some
embodiments, floor tile 100 may be a linoleum tile. The terms
"flooring tile" and "product" are used herein for convenience of
description only, and are intended to encompass surface coverings
that 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
products described herein are 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.
[0031] 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 on the second linoleum layer 130.
In some embodiments, a single homogenous linoleum core 151 may be
provided in lieu of a composite structure having a plurality of
linoleum layers.
[0032] 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 be placed adjacent a suitable support base or
underlayment. In the case of a flooring system, the support base
may be a subfloor.
[0033] 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.
[0034] In one non-limiting exemplary embodiment, the length and/or
width of the top major surface 101 of tile 100 is less than the
corresponding length and/or width of the bottom major surface 102
respectively. In another non-limiting exemplary embodiment, in
which tile 100 has isotropic edges (i.e. all the same edge
profile), both the length and width of the top major surface 101 of
tile 100 are less than the corresponding length and width of the
bottom major surface 102 respectively. In either of the foregoing
exemplary embodiments, the surface area defined by the top major
surface 101 is less than the surface area defined by the bottom
major surface 102. Accordingly, in either of the foregoing
exemplary embodiments, the peripheral edge surfaces 103 have an
"overcut" configuration where the bottom edge 105 of the tile
protrudes laterally beyond the top edge 104 (see, e.g. FIGS. 2 and
3).
[0035] Any suitable thickness of tile 100 may be used. Some
embodiments provide that the overall thickness of tile 100 may be
varied, e.g. about 2 mm being used for lighter wear applications
and greater thicknesses such as about 2.5 mm and about 3.2 mm being
used for more critical applications. However, in general, some
embodiments provide that tile 100 can have an overall thickness of
from about 1 mm to about 6 mm; alternatively from about 1.5 mm to
about 4 mm.
[0036] 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. In 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] Some embodiments provide that the first and/or second
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.
[0042] 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.
[0043] 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.
[0044] In some embodiments the wood flour may be made from a
hardwood or a softwood.
[0045] 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%.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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 second linoleum layer 130 may be greater than the thickness of
the first linoleum layer 120.
[0053] 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 layer.
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.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] In some embodiments, the carrier comprises polyethylene
terephthalate. In some embodiments, the carrier comprises
polyethylene terephthalate and fiberglass.
[0061] 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.
[0062] According to one aspect of the invention, the peripheral
edge surfaces 103 may be overcut and sloped outwards going from the
top major surface 101 to the bottom major surface 102. Edge
surfaces 103 are disposed at an angle A1 measured from the tile
bottom edge 105 between 0 and 90 degrees to a vertical reference
plane intersecting bottom edge 105 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 floor tile
100. Peripheral edge surfaces 103 may be planar and form an obtuse
angle A2 with respect to the top major surface 101 and an acute
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.
[0063] In some exemplary embodiments, without limitation, angle A1
may be from about 5 degrees to about 30 degrees, and alternatively
in certain embodiments from about 10 degrees to about 20 degrees.
In other embodiments, the overcut profile forms a top major surface
101 which is smaller 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 outward 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 top
edge 104 is inwardly offset from the bottom edge 105 with respect
to centerline CL of the tile.
[0064] Without intending to be bound by theory, the present
inventors believe that overcutting the peripheral edge surfaces 103
of tile 100 improves the dimensional stability of tile 100 by
creating free volume defined by a gap or space 106 proximate to the
top peripheral edges 104 around the top perimeter of the tile 100
which allows for expansion under high relative humidity conditions.
Advantageously, this allows MD and AMD edges to be directly abutted
during installation, permitting the use of non-square tiles that
can create a wide variety of patterns.
[0065] With continuing reference to FIG. 2, the perimeter gap 106
may have a substantially triangular shape in cross section with the
base of the triangle being formed adjacent the top edge 104 of tile
100 and the pointed tip by the support base or underlayment (e.g.
subfloor) on which the floor tile is placed. The gap 106 is
therefore widest adjacent the top edge 104 of the 100. The bottom
apex of the gap therefore is disposed at the base-to-tile interface
at the tile bottom edge 105. 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 forms 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).
[0066] In some embodiments, all peripheral edge surfaces 103 may be
angled so that the tile 100 has an overcut edge profile on all four
peripheral edge surfaces. 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.
[0067] In another aspect, the inventors have determined that
sealing the peripheral edge surfaces 103 of tile 100 after cutting
and/or filing the tile edges will act to minimize moisture
absorption by the tile which might cause distortion and contribute
to curling or doming. In one embodiment, 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.
[0068] According to another aspect of the invention, unidirectional
tile layout may be produced using non-square tiles 100. As shown in
the exemplary partial flooring layout in FIG. 7, using rectangular
or plank-shaped tiles 100, machine direction peripheral edge
surfaces 103 MD are directly abutted against across machine
direction peripheral edge surfaces 103 AMD. Significantly, MD edges
of two adjoining tiles may be directly abutted as illustrated.
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 100 (e.g. rectangular) may be mixed with square tiles 100'
(shown dashed) in a single flooring system as illustrated without
quarter turning or regard for which peripheral edge surfaces 103 MD
or AMD abut each other in the layout. This is possible due to more
uniform dimensional stability provided by overcut isotropic
peripheral edge surface profiles of tiles 100.
[0069] As shown in FIG. 8, a unidirectional tile layout may
therefore also be produced using square floor 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 to the tiles 100 according to the
present disclosure having more uniform dimensional stability in the
MD and AMD. Quarter turning tiles is therefore not required. FIG. 8
illustrates the tile orientation and layout possible, and the
directional arrows show MD and AMD for a few tiles 100. 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 tile
and the MD edge of one tile abuts the MD edge of another tile). The
direction of the tiles 100 laid may therefore be random.
[0070] An exemplary method for installing floor tiles according to
the present invention may include providing a plurality of floor
tiles 100. In one embodiment, the floor tiles are linoleum tiles.
In some embodiments, the 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).
[0071] The method continues with placing a first floor tile 100 on
a support base of 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.
[0072] Because the tiles 100 have isotropic edges which do not
require quarter turning during installation, like MD edges and like
AMD edges may be abutted against each other on the support base.
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. 8 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.
[0073] It will be appreciated that the foregoing method may be used
with square or non-square tiles and combinations thereof.
[0074] Advantageously, the floor tiles 100 and corresponding
flooring systems described herein remove the restrictions for
installing floors and shapes of tile which can be utilized due to
improved dimensional stability.
Example
[0075] The dimensional stability of exemplary surface coverings of
the present invention is evaluated against the dimensional
stability of comparative surface coverings at a temperature of
25.degree. C. and 80% relative humidity (RH). Table 1 (below)
describes the results of these evaluations. Specifically, the
dimensional stability values provided for Example I (Ex. I)
represent the average dimensional stability demonstrated by four
(4) surface coverings having a ten degree (10.degree.) overcut edge
profile on the peripheral surfaces; and the dimensional stability
values provided for Comparative Example I (Comp. Ex. I) represent
the average dimensional stability demonstrated by four (4) surface
coverings having a ten degree (10.degree.) undercut edge profile on
the peripheral surfaces. Similarly, the dimensional stability
values provided for Example II (Ex. II) represent the average
dimensional stability demonstrated by three (3) surface coverings
having a ten degree (10.degree.) overcut edge profile on the
peripheral surfaces; and the dimensional stability values provided
for Comparative Example II (Comp. Ex. II) represent the average
dimensional stability demonstrated by three (3) surface coverings
having a ten degree (10.degree.) undercut edge profile on the
peripheral surfaces. The composition and structure of all of the
surface coverings evaluated, aside from the peripheral edge surface
profiles, are identical.
TABLE-US-00001 TABLE 1 Dimensional Stability (%) Machine Across
Machine Example Scrim Direction Direction Ex. I Glass/PET 0.06 0.07
Comp. Ex. I Glass/PET 0.08 0.11 Ex. II PET/PET 0.09 0.10 Comp. Ex.
II PET/PET 0.09 0.15
[0076] As demonstrated by the data described in Table 1 (above),
exemplary surface coverings of the present invention having an
"overcut" peripheral edge surface profile provide more uniform MD
and AMD dimensional stability than the comparative surface
coverings which do not include an "overcut" peripheral edge surface
profile. The greater uniformity in MD and AMD dimensional stability
is evidenced by the lesser difference in MD and AMD dimensional
stability exhibited by the surface coverings of the present
invention.
[0077] 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.
* * * * *