Resilient floor tile and method of 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 resilient floor tile comprises a decorative layer comprising a printed ink forming a decorative pattern disposed between a base and a protective film layer; wherein the decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. The process for making a resilient floor tile comprises preheating a printed tile blank; cutting and molding the printed tile blank concurrently to form a resilient floor tile having a convex edge along a top, outer perimeter of the resilient floor tile.

1 - 45 . (canceled) 
     
     
         46 . A resilient floor tile, dimensioned and constructed for grouting comprising:
 a base comprising an organic polymer present at a level less than 34% by weight of the base, so that the tile has rigidity; and   a decorative layer,
 wherein the base and the decorative layer together form a resilient floor tile having: 
 a top surface with a contoured edge along its perimeter, which contoured edge has an outermost contoured surface, and 
 a bottom surface, 
 a vertical sidewall extending from the bottom surface of the tile to the outermost contoured surface, 
 wherein the decorative layer extends over at least a portion of the contoured edge, 
 and wherein the tile is constructed such that when the tile is grouted, the top level of the grout is below the top surface of the tile and the contoured edge extends above the top surface of the grout, so that there is no exposed edges where the outermost contoured edge meets the tile sidewall. 
   
     
     
         47 . The resilient floor tile of  claim 46 , wherein the organic polymer is a vinyl polymer. 
     
     
         48 . The resilient floor tile of  claim 46 , wherein the outermost contoured edge extends at least halfway down the tile sidewall, from the tile's top surface. 
     
     
         49 . The resilient floor tile of  claim 46 , wherein the outermost contoured edge extends at least 25% of the height of the tile, down the tile sidewall, from the tile's top surface. 
     
     
         50 . The resilient floor tile of  claim 46 , wherein the outermost contoured edge extends at least 75% of the height of the tile, down the tile sidewall, from the tile's top surface. 
     
     
         51 . The resilient floor tile of  claim 46 , wherein the outermost contoured edge extends at least 10% of the height of the tile, down the tile sidewall, from the tile's top surface. 
     
     
         52 . The resilient floor tile of  claim 46 , wherein the wherein the sidewall is substantially free from cracks and small holes. 
     
     
         53 . The resilient floor tile of  claim 46 , wherein the decorative layer extends over the entire outermost contoured surface. 
     
     
         54 . The resilient floor tile of  claim 46 , wherein the decorative layer extends over the entire contoured edge. 
     
     
         55 . The resilient floor tile of  claim 46 , wherein the vertical side wall is substantially solid in that it does not have preformed openings or openings of predetermined shapes or sizes. 
     
     
         56 . The resilient floor tile of  claim 46 , wherein the base further comprises one or more plasticizers. 
     
     
         57 . The resilient floor tile of  claim 46 , wherein the base further comprises one or more pigments. 
     
     
         58 . The resilient floor tile of  claim 46 , wherein the base is approximately 50-200 mils thick. 
     
     
         59 . The resilient floor tile of  claim 46 , wherein the tile has a thickness of approximately 4 mm. 
     
     
         60 . A resilient floor tile, dimensioned and constructed for grouting comprising:
 a base comprising organic polymer present at a level less than 34% by weight of the base, so that the tile has rigidity; and   a decorative layer,
 wherein the base, and the decorative layer together form a resilient floor tile having: 
 a top surface with a convex edge along its perimeter, which convex edge has an outermost convex surface, and 
 a bottom surface, 
 a vertical sidewall extending from the bottom surface of the tile to the outermost convex surface, 
 wherein the decorative layer extends over at least a portion of the convex edge, 
 and wherein the tile is constructed such that when the tile is grouted, the top level of the grout is below the top surface of the tile and the convex edge extends above the top surface of the grout, so that there is no exposed edges where the outermost convex edge meets the tile sidewall. 
   
     
     
         61 . The resilient floor tile of  claim 60 , wherein the polymer is a vinyl polymer. 
     
     
         62 . The resilient floor tile of  claim 60 , wherein the outermost convex edge extends at least halfway down the tile sidewall, from the tile's top surface. 
     
     
         63 . The resilient floor tile of  claim 60 , wherein the outermost convex edge extends at least 25% of the height of the tile, down the tile sidewall, from the tile's top surface. 
     
     
         64 . The resilient floor tile of  claim 60 , wherein the outermost convex edge extends at least 75% of the height of the tile, down the tile sidewall, from the tile's top surface. 
     
     
         65 . The resilient floor tile of  claim 60 , wherein the outermost convex edge extends at least 10% of the height of the tile, down the tile sidewall, from the tile's top surface. 
     
     
         66 . The resilient floor tile of  claim 60 , wherein the sidewall is substantially free from cracks and small holes. 
     
     
         67 . The resilient floor tile of  claim 60 , wherein the decorative layer extends over the entire outermost convex surface. 
     
     
         68 . The resilient floor tile of  claim 60 , wherein the decorative layer extends over the entire convex edge. 
     
     
         69 . The resilient floor tile of  claim 60 , wherein the vertical side wall is substantially solid in that it does not have preformed openings or openings of predetermined shapes or sizes. 
     
     
         70 . The resilient floor tile of  claim 60 , wherein the base further comprises one or more plasticizers. 
     
     
         71 . The resilient floor tile of  claim 60 , wherein the base further comprises one or more pigments. 
     
     
         72 . The resilient floor tile of  claim 60 , wherein the base is approximately 50-200 mils thick. 
     
     
         73 . The resilient floor tile of  claim 60 , wherein the tile has a thickness of approximately 4 mm. 
     
     
         74 . A flooring comprising a plurality of tiles of  claim 46  positioned adjacent to each other. 
     
     
         75 . The flooring of  claim 74  further comprising grout disposed between the tiles. 
     
     
         76 . The flooring of  claim 75  wherein the top surface of the grout is below the top surface of the tile and the contoured edge extends above the top surface of the grout, so that there is no exposed edges where the outermost contoured edge meets the tile sidewall. 
     
     
         77 . The flooring of  claim 74 , wherein the tiles are butt fit against each other. 
     
     
         78 . A flooring comprising a plurality of tiles of  claim 60  positioned adjacent to each other. 
     
     
         79 . The flooring of  claim 78  further comprising grout disposed between the tiles. 
     
     
         80 . The flooring of  claim 79  wherein the top surface of the grout is below the top surface of the tile and the contoured edge extends above the top surface of the grout, so that there is no exposed edges where the outermost contoured edge meets the tile sidewall. 
     
     
         81 . The flooring of  claim 78 , wherein the tiles are butt fit against each other.