Flooring element

Abstract

An apparatus for and a method of making a flooring element. The flooring element is a tile formed of a polymer with embedded filler material. The filler material includes abrasive particles adjacent the top surface and a resilient or rubber-like material. The bottom surface of the tile includes a plurality of particles embedded in and extending from the bottom, which enables the tile to be securely adhered to a substrate. One embodiment of a method of making the tile includes adding a first layer containing a filler material to a mold, vibrating the mold to cause the heavier filler material to sink, applying a plurality of particles to the top of the polymer mixture in the mold, and polymerizing the mixture in the mold. In another embodiment, a second layer including resilient particles is added to the mold above the first layer before the mold is vibrated.

1 . A flooring element comprising:
 a tile having a top surface and a bottom surface, said bottom surface being substantially planar, said tile formed as a single piece of a polymer having a first concentration of a plurality of first particles and a second concentration of said plurality of first particles, said plurality of first particles including a plurality of abrasion resistant particles, said first concentration greater than said second concentration, said first concentration proximate said top surface of said tile and said second concentration proximate said bottom surface; and   a plurality of second particles embedded in and extending from said bottom surface of said tile.   
     
     
         2 . The flooring element of  claim 1  wherein said tile includes a plurality of resilient material pieces embedded in said polymer. 
     
     
         3 . The flooring element of  claim 1  wherein selected portions of said top surface of said tile includes a photo-luminescent material. 
     
     
         4 . The flooring element of  claim 1  wherein said top surface of said tile includes a plurality of protrusions extending away from said bottom surface, said plurality of protrusions selected from a group including a plurality of blisters integral with said tile, a plurality of pre-formed reflective items embedded in said polymer, and a plurality of ridges integral with said tile. 
     
     
         5 . The flooring element of  claim 1  wherein said top surface of said tile includes a component to stabilize said top surface against ultra-violet light. 
     
     
         6 . A flooring element comprising:
 a mixture of a polymerizable resin, a hardener, and a filler material, said filler material including abrasion resistant particles, said flooring element having a thickness defining at least a first and a second region, wherein said first region has a concentration of said abrasion resistant particles that is greater than that of said second region.   
     
     
         7 . The flooring element of  claim 6  further including an upper surface and a lower surface, and wherein said first region is provided at the upper surface. 
     
     
         8 . The flooring element of  claim 7  further including a third region provided at said lower surface, wherein said third region has a concentration of said abrasion resistant particles that is greater than that of said second region. 
     
     
         9 . The flooring element of  claim 6  wherein said flooring element is a tactile tile. 
     
     
         10 . The flooring element of  claim 6  wherein said filler material comprises a first set of abrasion resistant particles and a second set of abrasion resistant particles, the first set of abrasion resistant particles having a density that is higher than that of the second set. 
     
     
         11 . The flooring element of  claim 10  wherein said first set of abrasion resistant particles includes one or both of sand and bauxite. 
     
     
         12 . The flooring element of  claim 10  wherein said second set of abrasion resistant particles includes a resilient material. 
     
     
         13 . The flooring element of  claim 6  wherein said mixture includes a photo-luminescent additive. 
     
     
         14 . The flooring element of  claim 6  wherein said mixture includes a component to stabilize said first region against the effects of ultra violet light. 
     
     
         15 . A method of making a flooring element including a mixture of a polymerizable resin, a hardener and a filler material, the filler material including abrasion resistant particles, the method comprising the steps of:
 a) providing a first layer of a mixture in a mold prior to polymerization of the mixture;   b) treating said mixture so that there is movement of the abrasion resistant particles to define at least a first and a second region of said mixture, wherein said first region has a concentration of abrasion resistant particles which is greater than that of said second region; and   c) polymerizing said first layer.   
     
     
         16 . The method of  claim 15  wherein said step b) of treating said mixture includes vibrating said mixture. 
     
     
         17 . The method of  claim 15  wherein the filler material includes a first set of abrasion resistant particles having a density that is higher than the density of at least the polymerizable resin such that said first set of abrasion resistant particles moves to a lower portion of a volume of said mixture during treatment of said mixture to define said first region. 
     
     
         18 . The method of  claim 17  wherein said first set of abrasion resistant particles includes one or both of sand and bauxite. 
     
     
         19 . The method of  claim 17  wherein the flooring element is formed upside down in the mold such that said first region is adjacent an upper surface of the flooring element, said upper surface configured to be tread upon. 
     
     
         20 . The method of  claim 19  further including the step of adding a third set of abrasion resistant particles to said mold during polymerization to define a third region of said mixture, said third region having a concentration of said abrasion resistant particles that is greater than that of said second region. 
     
     
         21 . The method of  claim 17  wherein the filler material includes a second set of abrasion resistant particles, said first set having a density that is higher than that of said second set. 
     
     
         22 . The method of  claim 21  further including the step of providing a second layer of said mixture in the mold prior to step c) of polymerizing said mixture, said second layer including said second set of abrasion resistant particles, said step c) of polymerizing including polymerizing said second layer. 
     
     
         23 . The method of  claim 22  further including the step of vibrating said mold to cause intermixing of the first and second layers. 
     
     
         24 . The method of  claim 21  wherein said second set of abrasion resistant particles includes a resilient material. 
     
     
         25 . The method of  claim 15  further including the step of providing at least one cavity at the mold to create at least one protrusion of the flooring element. 
     
     
         26 . The method of  claim 15  further including the step of pressing said mixture within said mold. 
     
     
         27 . The method of  claim 15  further including the step of adding a photo-luminescent additive to said mixture. 
     
     
         28 . The method of  claim 15  wherein the viscosity of said mixture is adjusted. 
     
     
         29 . The method of  claim 15  further including the step of adding to said mixture a component to stabilize said first layer against the effects of ultra violet light. 
     
     
         30 . A method of making a flooring element, said method comprising the steps of:
 a) adding a first layer to a mold, said first layer including a resin, a hardener, and a plurality of first particles, said mold having a shallow and substantially planar cavity configured to receive said first layer, said mold having a bottom that corresponds to a top of said flooring element, said plurality of first particles including abrasion resistant material;   b) vibrating said mold until a substantial portion of said plurality of first particles are located adjacent said bottom of said mold;   c) adding a plurality of second particles to a top surface of a mixture in said mold, said mixture including said first layer, said plurality of second particles being partially embedded in said top surface and extending from said top surface; and   d) polymerizing said mixture in said mold.   
     
     
         31 . The method of  claim 30  further including, after said step d) of polymerizing, a step e) of removing said mixture from said mold and a step f) of storing said mixture on a flat horizontal surface for a specified time. 
     
     
         32 . The method of  claim 30  wherein said first layer includes a plurality of resilient particles. 
     
     
         33 . The method of  claim 30  further including a step al) of adding a second layer to said mold after said step a), said second layer including a resin, a hardener, and a plurality of resilient particles, said mixture including said second layer. 
     
     
         34 . The method of  claim 30  further including a step of adjusting a viscosity of said first layer before said step b) of vibrating. 
     
     
         35 . The method of  claim 30  further including, before said step a) of adding said first layer, a step of adding a pre-formed reflective item to said mold. 
     
     
         36 . The method of  claim 30  further including a step of adjusting a viscosity of said first layer before said step b) of vibrating, said viscosity adjusted by controlling one or both of a temperature of said first layer and a ration of said resin to said hardener. 
     
     
         37 . The method of  claim 30  wherein said mold includes a bottom having a plurality of depressions configured to form a plurality of features selected from a plurality of blisters and a plurality of ridges. 
     
     
         38 . The method of  claim 30  wherein said first layer includes one or both of a photo-luminescent material and a component to stabilize said top surface against ultra-violet light.