Abstract: An inlaid tile composition and a method for making the composition in which filled colored polymeric chips are uniformly dispersed throughout a filled thermoplastic tile base is disclosed. In an alternative embodiment, colored, coated mineral chips of a mineral such as quartz are uniformly dispersed throughout a filled thermoplastic tile base. The chips are coated by a ceramic technique or with a pigmented polyester or epoxy resin. Alternatively, a mixture of coated mineral chips and partially cross linked resinous chips may be employed. In a further embodiment, additional chips may be spread on the top surface of the formed sheet and pressed in with a roller, prior to the final calendering step. The tile base may contain a lubricant to reduce processing temperatures and shear forces in the intensive mixer.

Abstract: A tile composition having a unique appearance created by the use of inlaid particles over an embossed and printed pattern is disclosed. In preparing the tile product, a first layer of UV curable coating is applied over the entire upper surface of a tile base. An excess of particles or chips is then sprinkled onto the surface of the first coating layer and the non-adhering particles are removed. The first layer is subjected to curing and a second layer of UV curable coating is then applied over the particles and the first layer followed by a second curing step. In one embodiment, the second coating is obtained by a combination of coating methods, including one or more direct roll coating steps followed by a curtain coating step. The particles or chips should preferably include chips of three types: (a) pigmented base color chips of which about 77 to 100 weight percent are of a U.S. mesh size in the range of between 60 and 200; (b) clear chips of which about 77 to 100 weight percent are of a U.S.

Abstract: An inlaid tile composition in which filled colored polymeric chips are uniformly dispersed throughout a filled thermoplastic tile base is disclosed. The chips remain discrete during temperture processing in an intensive mixer such as a Banbury mixer, without smearing or elongation of the chips during processing. The tile base may contain a lubricant to reduce processing temperatures in the intensive mixer.