Abstract: Disclosed herein are tiles, systems, and methods related to manufacturing bullnose or other non-straight edge tiles. The tiles can comprise a non-straight edge with one or more printed layers. The printed layers can comprise radiation curable inks or other fast-drying coatings. Upon exposure to a curing station, the layers cure quickly. This provides a printed and cured surface that very closely matches the rest of the tile. The tiles, systems, and methods disclosed herein can be of higher quality and can involve more efficient manufacturing than existing tiles, systems, and methods.

Abstract: Composite tile systems and methods are disclosed. Embodiments of this disclosure can comprise a composite floor tile having a ceramic upper layer with one or more reinforcing layers. The reinforcing layer or layers can comprise a reinforcing material, such as fiberglass, and an adhesive. An under layer can be disposed under, or integrated with, the reinforcing layer, and can comprise a ceramic or a polymer laminate. A bottom layer can comprise a pressure sensitive adhesive, or other adhering system, that attaches to various substrates. Embodiments of this disclosure can improve ease of installation of tile, improve strength of tile, and reduce the weight of tile, among other advantages.

Abstract: A tile system, comprising: —a mounting unit, e.g. a rail fixed to a wall; —a tile unit, e.g. a frame holding a decorative tile; —a tile unit-fastening device configured to fasten the tile unit to the mounting unit, e.g. a pin engaging recesses formed on the mounting and the tile unit, the tile unit-fastening device preferably comprising a repositioning mechanism configured to allow the tile unit to move in one or two directions parallel to the wall after the tile unit is fastened to the mounting unit, e.g. the pin having ribs on its outer surface and the recesses being elongated and having cooperating ribs on their elongated inner faces.

Abstract: The various embodiments of the present invention are directed to wear resistant coatings, tiles having the wear resistant coatings disposed thereon, and to methods of making the coatings and tiles. A wear resistant coating generally includes a strontium aluminosilicate glass-ceramic composition that is formed from a glaze. The glaze can include a crystallizing component, which itself can include strontium, aluminum, and silicon, but also comprises less than about 2 weight percent each of lithium, boron, barium, sodium, iron, titanium, zirconium, and carbon, based on a total weight of the crystallizing component.

Abstract: The various embodiments of the present invention are directed to floating floor systems and to methods of making and using the floor systems. The floating floor systems generally include a floating flooring unit (704) and a mechanical-energy-harvesting device (710). The mechanical-energy-harvesting device can be incorporated into the flooring unit component at a variety of locations. The floor systems can further include an energy storage device (712) and/or an electronic component that will be actuated or driven by the electricity generated.

Abstract: A groutless tile system including groutless tiles, wherein each groutless tile includes a substrate, a durable surface disposed within a groove defined by the substrate, the durable surface having bottom surface, and a first coupling member disposed on an edge of the substrate. The first coupling member comprises a first bendable portion and a groove, the groove having an upper surface and a lower surface. The bottom surface of the durable surface is substantially coplanar with a point between the upper and lower surfaces of the groove. To provide for various mechanical benefits, one or more surfaces of the groutless tile can be encapsulated in one or more polymers.

Abstract: The various embodiments of the present invention are directed to tile systems and to methods of making and using the tile systems. The tile systems provide improved thermal properties to floor and wall coverings in either heated or unheated applications. The tile systems generally include a tile and a discrete phase change material.

Abstract: A groutless tile system including groutless tiles, wherein each groutless tile includes a substrate, a durable surface disposed within a groove defined by the substrate, the durable surface having bottom surface, and a first coupling member disposed on an edge of the substrate. The first coupling member comprises a first bendable portion and a groove, the groove having an upper surface and a lower surface. The bottom surface of the durable surface is substantially coplanar with a point between the upper and lower surfaces of the groove.

Abstract: A groutless tile system including groutless tiles, wherein each groutless tile includes a substrate, a durable surface disposed within a groove defined by the substrate, the durable surface having bottom surface, and a first coupling member disposed on an edge of the substrate. The first coupling member comprises a first bendable portion and a groove, the groove having an upper surface and a lower surface. The bottom surface of the durable surface is substantially coplanar with a point between the upper and lower surfaces of the groove. The polymer matrix forming at least a portion of the substrate can be modified to reduce the weight of the groutless tile or the cost to manufacture the groutless tile. In some embodiments, the polymer matrix is modified through the use of gas nucleation or a blowing agent.

Abstract: The various embodiments of the present invention are directed to floating floor systems and to methods of making and using the floor systems. The floating floor systems generally include a floating flooring unit (704) and a mechanical-energy-harvesting device (710). The mechanical-energy-harvesting device can be incorporated into the flooring unit component at a variety of locations. The floor systems can further include an energy storage device (712) and/or an electronic component that will be actuated or driven by the electricity generated.

Abstract: A tile system, comprising: —a mounting unit, e.g. a rail fixed to a wall; —a tile unit, e.g. a frame holding a decorative tile; —a tile unit-fastening device configured to fasten the tile unit to the mounting unit, e.g. a pin engaging recesses formed on the mounting and the tile unit, the tile unit-fastening device preferably comprising a repositioning mechanism configured to allow the tile unit to move in one or two directions parallel to the wall after the tile unit is fastened to the mounting unit, e.g. the pin having ribs on its outer surface and the recesses being elongated and having cooperating ribs on their elongated inner faces.

Abstract: A groutless tile system including groutless tiles, wherein each groutless tile includes a substrate, a durable surface disposed within a groove defined by the substrate, the durable surface having bottom surface, and a first coupling member disposed on an edge of the substrate. The first coupling member comprises a first bendable portion and a groove, the groove having an upper surface and a lower surface. The bottom surface of the durable surface is substantially coplanar with a point between the upper and lower surfaces of the groove.

Abstract: A method for making a groutless tile including: providing a durable surface; molding a substrate to receive at least a portion of the durable surface; affixing the durable surface to the substrate; and milling at least a portion of the substrate to create a first coupling member on an edge of the substrate and a second coupling member on a opposing edge of the substrate.

Abstract: A groutless tile system including: a plurality of groutless tiles, wherein each groutless tile includes: a durable surface disposed on a substrate; and a first coupling member disposed on an edge of the substrate; wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and a second coupling member of an adjacent tile are operable for coupling adjacent groutless tiles, and wherein the substrate prevents the durable surfaces of adjacent groutless tiles from contacting one another.

Abstract: A component recovery process to recover one or more of the constituent components of a feed material. In one embodiment, the process is a carpet recycling process, the feed material being carpet, and the constituent components being fiber, filler and adhesive. The process can refine the polypropylene backing polymer and face fibers of post industrial edge trim selvage, whole carpet construction post industrial scraps and pieces, as well as whole carpet post consumer scraps and pieces and in particular mixtures there of. The process beneficially uses land filled edge trim and pre land filled selvage, whole carpet construction scraps and whole carpet post consumer scraps and mixtures there of for component purification.

Abstract: The various embodiments of the present invention are directed to wear resistant coatings, tiles having the wear resistant coatings disposed thereon, and to methods of making the coatings and tiles. A wear resistant coating generally includes a strontium aluminosilicate glass-ceramic composition that is formed from a glaze. The glaze can include a crystallizing component, which itself can include strontium, aluminum, and silicon, but also comprises less than about 2 weight percent each of lithium, boron, barium, sodium, iron, titanium, zirconium, and carbon, based on a total weight of the crystallizing component.

Abstract: A groutless tile system including: a plurality of groutless tiles, wherein each groutless tile includes: a durable surface disposed on a substrate; and a first coupling member disposed on an edge of the substrate; wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and a second coupling member of an adjacent tile are operable for coupling adjacent groutless tiles, and wherein the substrate prevents the durable surfaces of adjacent groutless tiles from contacting one another.

Abstract: A carpet tile and process for making the carpet tile, wherein the carpet tile contains tufted face yarn, a primary backing, and at least three polymer-containing layers. The first layer is a pre-coat layer, and the second and third layers each contain a solventless hot melt adhesive that is extruded onto the pre-coat layer.

Abstract: A system and method for producing multi-colored carpets using a tufting machine. The present invention features a system and method for: providing a multi-colored pattern which is analyzed for validity with reference to a particular tufting machine; collecting parameters concerning a particular tufting machine; determining the colors of yarn to load with each needle of the particular tufting machine; and generating a report including a palette of colors used within the pattern, a chart indicating which color of yarns are used within each needle position, and a summary of the number of yarn cones needed to create a carpet of a predetermined size with the particular tufting machine.

Abstract: A woven carpet backing may include monofilament warp yarns and alternating monofilament and multifilament fill yarns. The yarns may be woven using a weave, such as a non-traditional weave, that places all of the multifilament fill yarns on the face of the fabric and all of the monofilament fill yarns on the back of the fabric. Monofilament fill yarns and multifilament fill yarns are overstuffed, thereby creating a coverage factor greater than one hundred percent. The invention results in a carpet backing with the appearance of a primary carpet backing on one side of the fabric and the appearance of a secondary carpet backing on the opposite side of the fabric. The need for a secondary carpet backing is eliminated by the woven carpet backing.