Resilient floor tile and method of making the same

Abstract

A resilient floor tile includes a base layer, a film layer, a decorative film layer, and a topcoat. The resilient floor tile has a shaped edge formed on an upper surface thereof that extends about at least a portion of a perimeter of the resilient floor tile. In order to make the resilient floor tile, a continuous sheet of a base layer is conveyed into a press die. The press die is actuated from an open position to a closed position. The continuous sheet is cut with a blade of a cutting tool of the press die to form side surfaces of the resilient floor the when the press die is in the closed position. A shaped edge is formed on at least a portion of a perimeter of an upper surface of the resilient floor tile with a forming tool of the press die when the press die is in the closed position.

1 . A resilient floor tile comprising a base layer, a film layer and a topcoat, wherein the base layer, having a top surface and a bottom surface, has side walls that are substantially vertical between the top surface and the bottom surface, wherein the side walls have a recessed portion formed therein. 
     
     
         2 . The floor tile of  claim 1  wherein the recessed portion is substantially concave in shape. 
     
     
         3 . The floor tile of  claim 1  wherein the recessed portion has a depth of up to about 20 mils. 
     
     
         4 . The floor tile of  claim 1  wherein the recessed portion has a maximum depth between about 15 and about 20 mils. 
     
     
         5 . The floor tile of  claim 1  wherein the base layer comprises less than about 36 wt % of a binder, and at least about 64 wt % of a filler. 
     
     
         6 . The floor tile of  claim 1  wherein the floor tile further comprises a decorative film layer. 
     
     
         7 . The floor tile of  claim 1  wherein the topcoat comprises an acrylated urethane or acrylated polyester. 
     
     
         8 . The floor tile of  claim 1  wherein the floor tile has an upper surface that is formed by the topcoat, wherein the upper surface has top edges and at least one of the edges is shaped to have a substantially rounded or convex shape. 
     
     
         9 . The floor tile of  claim 1  wherein the floor tile has a substantially square shape and a thickness of about 100-175 mils. 
     
     
         10 . The floor tile of  claim 5  wherein the binder comprises a vinyl resin. 
     
     
         11 . The floor tile of  claim 8  wherein the recessed portion is substantially concave in shape. 
     
     
         12 . The floor tile of  claim 11  wherein the recessed portion has a depth of up to about 20 mils. 
     
     
         13 . The floor tile of  claim 1  wherein the recessed portion is adapted to receive a grout. 
     
     
         14 . The floor tile of  claim 12  wherein the recessed portion is adapted to receive a grout. 
     
     
         15 . The floor tile of  claim 1  wherein the side walls have non-recessed portions and the non-recessed portions of the side walls of two adjacent floor tiles make an adjoining fit when placed abuttingly against each other. 
     
     
         16 . The floor tile of  claim 1  wherein a shaped edge is formed at an end of the topcoat, which meets the side wall and forms an end portion, and wherein the end portions of two adjacent floor tiles make an adjoining fit when placed abuttingly against each other. 
     
     
         17 . A resilient floor tile comprising a base layer, wherein the base layer is resilient, and has a top surface and a bottom surface, wherein the base layer has side walls that are substantially vertical between the top surface and the bottom surface, and wherein the side walls have a recessed portion formed therein. 
     
     
         18 . The floor tile of  claim 17  wherein the recessed portion is substantially concave in shape. 
     
     
         19 . The floor tile of  claim 17  wherein the recessed portion has a depth of up to about 20 mils. 
     
     
         20 . The floor tile of  claim 17  wherein the recessed portion is adapted to receive a grout.