Resilient floor tile and method for making same

Abstract

A resilient floor tile is described that comprises a base; a protective film layer; and a decorative layer disposed between the base and the protective film layer; wherein the resilient floor tile has a top surface and a convex edge along a perimeter of the top surface. In another embodiment, the decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. In another embodiment, the resilient floor tile comprises an imprint having a predetermined pattern in a top surface of the floor tile that allows the floor tile to be separated along the imprint into smaller floor tiles. The process for making a resilient floor tile according to the various embodiments is described.

1 . A process for making a resilient floor tile, comprising: 
 preheating a printed tile blank;    cutting said printed tile blank; and    molding said printed tile blank to form a convex edge along a top, outer perimeter of said printed tile blank;    wherein said cutting and molding are performed concurrently to form a resilient floor tile.    
     
     
         2 . The process of  claim 1 , wherein said preheating comprises heating said printed tile blank to a temperature of approximately 100-200° F. to sufficiently soften said printed tile blank.  
     
     
         3 . The process of  claim 2 , wherein said heating comprises heating said printed tile blank to a temperature of approximately 125-135° F.  
     
     
         4 . The process of  claim 1 , further comprising repeating said preheating, said cutting, and said molding for a second printed tile blank.  
     
     
         5 . The process of  claim 1 , wherein said preheating comprises conveying said printed tile blank through an oven; said cutting and molding comprise cutting and molding in a press; and further comprising: 
 destacking said printed tile blank prior to said preheating;    conveying said printed tile blank from the oven to a press;    ejecting said resilient floor tile and a frame from the press;    conveying said frame to a waste bin; and    conveying said resilient floor tile to a counter-stacker.    
     
     
         6 . The process of  claim 1 , wherein said printed tile blank is uncoated and further comprising coating said printed tile blank to form a top coat after said cutting and said molding with a thermoset coating.  
     
     
         7 . A process for making a resilient floor tile, comprising: 
 means for softening a printed tile blank;    means for forming a resilient floor tile having a convex edge along an outer perimeter of said resilient floor tile from said printed tile blank.    
     
     
         8 . A process for making a resilient floor tile, comprising: 
 preheating a printed tile blank;    cutting said printed tile blank; and    molding said printed tile blank to form a convex edge along a top, outer perimeter of said printed tile blank and an imprint having a predetermined pattern in a top surface of said tile blank;    wherein said cutting and molding are performed concurrently to form a resilient floor tile.    
     
     
         9 . The process of  claim 8 , wherein said preheating comprises heating said printed tile blank to a temperature of approximately 100-200° F. to sufficiently soften said printed tile blank.  
     
     
         10 . The process of  claim 9 , wherein said heating comprises heating said printed tile blank to a temperature of approximately 125-135° F.  
     
     
         11 . The process of  claim 8 , where said molding further comprises forming a convex edge along said imprint.  
     
     
         12 . The process of  claim 8 , further comprising repeating said preheating, said cutting, and said molding for a second printed tile blank.  
     
     
         13 . The process of  claim 8 , wherein said preheating comprises conveying said printed tile blank through an oven; said cutting and molding comprise cutting and molding in a press; and further comprising: 
 destacking said printed tile blank prior to said preheating;    conveying said printed tile blank from the oven to a press;    ejecting said resilient floor tile and a frame from the press;    conveying said frame to a recycle bin; and    conveying said resilient floor tile to a counter-stacker.    
     
     
         14 . The process of  claim 8 , wherein said printed tile blank is uncoated and further comprising coating said printed tile blank to form a top coat after said cutting and said molding with a thermoset coating.  
     
     
         15 . A process for making a resilient floor tile, comprising: 
 means for softening a printed tile blank;    means for forming a resilient floor tile having a convex edge along an outer perimeter of said resilient floor tile and an imprint having a predetermined pattern in a top surface of said resilient floor tile from said printed tile blank.