LINOLEUM BASED SURFACE COVERINGS WITH EDGE DETAIL

Abstract

Described herein are surface coverings comprising: a linoleum core; a first major surface terminating at a first edge, a second major surface terminating at a second edge, and a peripheral edge surface extending between the first and second edges; wherein the peripheral edge surface is planar and oriented obliquely to the first major surface and the second major surface. Methods of making and using these surface coverings are also described.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/062,528 filed on Oct. 10, 2014. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present invention relates to surface covering systems, and more particularly to linoleum based floor tiles having edge detail.

BACKGROUND

The ability of a floor covering product to remain substantially flat under varying environment conditions is desirable. Dimensional stability (DS) is one applicable measure of floor covering products which may include linoleum panels or tiles. In short, dimensional stability quantifies the characteristic of a floor tile subjected to environmental changes in factors such as ambient relative humidity to remain relatively true to its original shape and dimensions. Excessive growth or shrinkage in dimension may adversely cause curling or doming in individual tiles under low or high relative humidity respectively. Curling or cupping causes the edges of the tile to curl upwards with respect to the central portion of the tile. Conversely, doming causes the portions of the tile to bow or bubble upwards with respect to the edges. Industry standards such as ASTM F2195-13 or others have been developed to measure the dimensional stability of floor tiles and set applicable performance levels.

In the production of linoleum floor tiles, continuous formation processes are sometimes used. A relatively wide continuous roll or sheet of linoleum is produced which moves longitudinally along a transport system, typically comprising calenders, rollers and/or conveyors, that defines a machine direction (“MD”). Smaller individual tiles are then cut from the larger material sheet by making cuts both along the machine direction and across machine direction (“AMD”). The MD and AMD are generally defined as being perpendicular to each other. The dimensional stability (DS) varies in both the MD and AMD of the floor product so that each is typically tested and measured separately, with AMD DS typically having a higher value showing poorer performance in that direction of the tile. Ideally, both MD DS and AMD DS should be below the applicable maximums set by industry standard and relatively close in value as possible which is indicative of DS uniformity of the flooring product and resistance to curling and doming.

Different edge details have sometimes been used for edges cut in the machine direction versus those cut across machine direction to mask dimensional stability differences between the MD and AMD edges of the floor tiles.

Improvement in dimensional stability of flooring products is desirable.

SUMMARY

In some embodiments, the present invention provides a floor tile with improved dimensional stability that overcomes the foregoing design limitations. In certain embodiments, the floor tile comprises linoleum. In some embodiments, the floor tiles may have isotropic edges (i.e. the cross sectional edge profile is identical on all sides). This eliminates a need to use differential MD and AMD edge details for masking dimensional stability differences in the MD versus AMD directions. Accordingly, special tile fabrication techniques previously used to mask dimensional stability differences are no longer required.

Advantageously, the present invention allows unidirectional installation of tiles in the flooring system so that MD edges may be directly abutted against MD edges, and AMD edges may be directly abutted against AMD edges without detriment. In addition, the present invention permits the manufacture and installation of non-square tiles (e.g. rectangular and plank shapes) to form a variety of aesthetic visual patterns because like MD-MD edges and/or like AMD-AMD edges may be in direct contact without adversely affecting dimensional stability. Heretofore, such tile shapes were generally unobtainable. Some embodiments of the present invention allow a wide variety of floor patterns to be formed using non-square tiles, such as without limitation a herringbone, a subway or running bond tile layout (i.e. longitudinally offset joints between adjoining rows of tiles), etc. Accordingly, tile installation techniques and patterns are not strictly limited to square grid patterns of the past.

In some embodiments, the present invention provides a surface covering comprising a linoleum core, a first major surface terminating at a first edge, a second major surface terminating at a second edge, and a peripheral edge surface extending between the first and second edges. The peripheral edge surface is planar and oriented obliquely to the first major surface and the second major surface. In certain embodiments, the peripheral edge surface is at an acute angle with the first major surface and an obtuse angle with the second major surface.

In some embodiments, the surface coverings of the present invention comprise a linoleum core. In some embodiments, the linoleum core comprises a plurality of layers. In some embodiments, the linoleum core comprises a first linoleum layer and a second linoleum layer. In some embodiments, the first linoleum layer comprises a first linoleum composition. In some embodiments, the second linoleum layer comprises a second linoleum composition. In some embodiments, the first linoleum layer comprises a first linoleum composition and the second linoleum layer comprises a second linoleum composition.

In some embodiments, the present invention provides a surface covering comprising a linoleum core, a first major surface terminating at a first edge, a second major surface terminating at a second edge, and a peripheral edge surface extending between the first and second edges, the first major surface being arranged parallel to the second major surface, the first major surface defining a first surface area, the second major surface defining a second surface area, and a carrier. In some embodiments, the carrier is embedded, at least partially, in the linoleum core. In some embodiments, the first surface area and the second surface area are different.

In some embodiments, the present invention provides a floor covering system comprising a plurality of floor tiles arranged edge-to-edge on a support base, each tile comprising a linoleum core, a top major surface terminating at a top edge, a bottom major surface terminating at a bottom edge, and a peripheral edge surface extending between the top and bottom edges, and a carrier. In some embodiments, the carrier is embedded, at least partially, in the linoleum core. The peripheral edge surface is planar and oriented obliquely to the top and bottom major surfaces. A gap is formed between adjoining tiles between the peripheral edge surfaces of the tiles, the gap having a greater width between the bottom edges of adjoining tiles at the support base than at the top edges.

In some embodiments, the present invention provides a floor tile comprising: a carrier; a linoleum core; a polymeric wear layer disposed on the linoleum core; a top major surface terminating at a plurality of top edges, a bottom major surface terminating at a plurality of bottom edges, and a plurality of peripheral edge surfaces extending between the top and bottom edges around a perimeter of the tile; the top major surface being arranged parallel to the bottom major surface; the wear layer defining the top major surface; wherein the top major surface has a first area and the bottom major surface has a second area, the second area being less than the first area.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the exemplary embodiments of the present invention will be described with reference to the following drawings, where like elements are labeled similarly, and in which:

FIG. 1 is a top plan view of a prior art quarter turned flooring system;

FIG. 2 is a side elevation cross-sectional view of a floor tile for use in a flooring system according to the present disclosure;

FIG. 3 is an exploded view of the floor tile of FIG. 2;

FIG. 4 is a top plan view of an exemplary floor tile of the present invention having a square configuration and showing the fabrication process material flow, or machine direction;

FIG. 5 is a top plan view of an exemplary floor tile of the present invention having a non-square configuration and showing the fabrication process material flow, or machine direction;

FIG. 6 is a top plan view of an exemplary carrier of the present invention;

FIG. 7 is an exemplary flooring system with a pattern formed by using exemplary square tiles of the present invention; and

FIG. 8 is a side view of two adjoining abutting floor tiles placed on a common support base.

All drawings are schematic and not necessarily to scale. Parts given a reference numerical designation in one figure may be considered to be the same parts where they appear in other figures without a numerical designation for brevity unless specifically labeled with a different part number and described herein.

DETAILED DESCRIPTION

The features and benefits of the invention are illustrated and described herein by reference to non-limiting exemplary embodiments. This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features.

In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

FIGS. 2-5 depict non-limiting exemplary embodiments of a surface covering such as without limitation a floor tile 100 in accordance with principles of the present invention. Floor tile 100 may be used for forming a flooring system comprised of a plurality of tiles laid with abutting joints between tiles. In some embodiments, the floor tile 100 may be a linoleum tile. The terms “flooring tile” and “product” is used herein for convenience of description only, such flooring products may be applied to any suitable type and oriented surface including without limitation horizontal, vertical, and/or angled or sloped surfaces. Application surfaces or substrates to which the flooring product is mounted may include floors, walls, countertops, ceilings, and others. Accordingly, the invention and non-limiting embodiments of the flooring products described herein are not limited in their application or use strictly to flooring systems alone.

In some embodiments, the surface coverings of the present invention comprise a linoleum core. In some embodiments, the linoleum core comprises a plurality of layers. In some embodiments, the linoleum core comprises a first linoleum layer and a second linoleum layer. In some embodiments, the first linoleum layer comprises a first linoleum composition. In some embodiments, the second linoleum layer comprises a second linoleum composition. In some embodiments, the first linoleum layer comprises a first linoleum composition and the second linoleum layer comprises a second linoleum composition.

In some embodiments, for example those described in FIGS. 2-5, floor tile 100 may comprise (from the bottom upwards) a carrier 110, a linoleum core 150, the linoleum core 150 comprising a first (or bottom) linoleum layer 120 disposed on the carrier, a second (or top) linoleum layer 130 disposed on the first linoleum layer, and a coating 140 disposed thereon. In some embodiments, a single homogenous linoleum core 151 may be provided in lieu of a composite structure having a plurality of linoleum layers.

In some embodiments, the second linoleum layer may be a visual linoleum layer in which various decorative additives may be incorporated to create the visual. In some embodiments, wherein the carrier is embedded in the first linoleum layer, the first linoleum layer may form the bottom major surface, which may be placed adjacent a suitable support base or underlayment. In the case of a flooring system, the support base may be a subfloor.

In some embodiments, tile 100 further includes a top major surface 101, an opposing bottom major surface 102, and peripheral edge surfaces 103 extending between the top and bottom major surfaces around the perimeter of tile 100. The top and bottom extremities of peripheral edge surfaces 103 define top and bottom edges 104 and 105, respectively which similarly extend around the entire perimeter of tile 100. Top and bottom edges 104, 105 and peripheral edge surfaces 103 collectively define two pairs of opposing parallel MD and AMD edges for each tile 100 that extend between the top and bottom major surfaces 101, 102. In some embodiments, tile 100 further comprises a length L and width W measured in the horizontal plane along the top and bottom major surfaces 101, 102. In various embodiments, length L and width W may be substantially equal or different.

Any suitable thickness of linoleum floor tile 100 may be used. Some embodiments provide that the overall thickness of the floor tile 100 may be varied, e.g. 2 mm being used for lighter wear applications and greater thicknesses such as 2.5 mm and 3.2 mm being used for more critical applications. However, in general, some embodiments provide that the tile 100 can have an overall thickness of from 1 mm to 6 mm; alternatively from 1.5 mm to 4 mm.

In some embodiments, the first linoleum composition comprises: linoleum cement, a first organic filler, and a first inorganic filler. In some embodiments, the second linoleum composition comprises: linoleum cement, a second organic filler, and a second inorganic filler. According to some embodiments, the second linoleum composition may have relatively lower concentrations of linoleum cement and relatively higher concentrations of organic filler than the first linoleum composition. In some embodiments, the enhanced dimensional stability is the result of reduced sensitivity to changes in moisture. In other words, as relative humidity of the surrounding environment increases or decreases, the linoleum core is less likely to “dome” at high humidity and “curl” at low humidity.

In some embodiments, the first linoleum composition comprises from about 30 wt. % to about 45 wt. % of linoleum cement, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises about 41 wt. % of linoleum cement, based on the total weight of the first linoleum composition.

In some embodiments, the first linoleum composition comprises from about 18 wt. % to about 42 wt. %, preferably from about 20 wt. % to about 30 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 0.5 μm to about 20 μm. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 μm to about 10 μm. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 μm to about 5 μm.

Some embodiments provide that the first inorganic filler may comprise limestone powder (calcium carbonate powder), chalk powder, kaolin clay, silica, vermiculite, ball clay or bentonite, talc, mica, gypsum, perlite, titanium dioxide, sand, barium sulfate, dolomite, wollastonite, calcite, pigments, zinc oxide, zinc sulfate, or a combination of two or more thereof.

In some embodiments, the first linoleum composition comprises from about 7 wt. % to about 30 wt. %, preferably from about 15 wt. % to about 30 wt. % of a first organic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 18 wt. % to about 23 wt. % of the first organic filler, based on the total weight of the first linoleum composition.

Some embodiments provide that the first and/or second organic filler comprises a cellulosic, a polymeric material, a non-polymeric material, or a combination of two or more thereof. In some embodiments, the first and/or second organic filler may be a fibrous material or a particulate material. In some embodiments, the first and/or second organic filler comprises a cellulosic material selected from wood fibers, cork, wood shavings, wood flour, paper fibers, cotton linters, a combination of two or more thereof.

In some embodiments the wood flour may be made from a hardwood or a softwood. In some embodiments, the wood flour comprises particles having a particle size distribution as follows: <160 μm: 40-90%, and <80 μm 10-50%. In other embodiments, the wood flour comprises particles having a particle size distribution as follows: <160 μm 50-85%; and <80 μm 10-30%.

The polymeric material may include polyolefin, and the non-polymeric material may include a hydrophobic material. In some embodiments, the hydrophobic material has a melting point below 100° C. In some embodiments, the non-polymeric material is selected from Montan wax; Carnauba wax; bee wax; paraffin; and a combination of two or more thereof.

In some embodiments, the non-polymeric material may be present in an amount ranging from about 0.1 wt. % to about 1 wt. % based on the total weight of the first linoleum composition. In some embodiments, the non-polymeric material may be present in an amount ranging from about 0.1 wt. % to about 0.6 wt. % based on the total weight of the first linoleum composition.

In some embodiments, the thickness of the first linoleum layer 120 may be varied and range from about 0.5 mm to about 5 mm; alternatively from about 0.75 mm to about 3 mm; alternatively from about 0.9 mm to about 1.1 mm.

In some embodiments, the second linoleum composition comprises: from about 17.5 wt. % to about 70 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 25 wt. % to about 45 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 30 wt. % to about 40 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 36 wt. % of linoleum cement, based on the total weight of the second linoleum composition.

In some embodiments, the second linoleum composition comprises from about 10 wt. % to about 20 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 12 wt. % to about 18 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 14 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition.

Some embodiments provide that the second inorganic filler may include limestone powder (calcium carbonate powder), chalk powder, kaolin clay, silica, vermiculite, ball clay or bentonite, talc, mica, gypsum, perlite, titanium dioxide, sand, barium sulfate, dolomite, wollastonite, calcite, pigments, zinc oxide, and zinc sulfate, or a combination of two or more thereof.

Some embodiments provide that the second linoleum composition comprises a second organic filler. In some embodiments, the second linoleum composition comprises from about 30 wt. % to about 45 wt. % of a second organic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 36 wt. % to about 41 wt. % of the second organic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 39 wt. % of the second organic filler, based on the total weight of the second linoleum composition.

In some embodiments, the thickness of the second linoleum layer 130 may be varied and range from about 0.5 mm to about 5 mm; alternatively from about 0.75 mm to about 3 mm; alternatively from about 1.1 mm to about 1.4 mm. In certain embodiments, the thickness of the second linoleum layer 130 may be greater than the thickness of the first linoleum layer 120.

In some embodiments, such as described in FIGS. 2 and 3, the surface covering may further comprise a coating 140. In some embodiments, coating 140 may perform as a wear layer. In some embodiments, coating 140 is applied to the second linoleum composition. In some embodiments, coating 140 is UV curable, moisture curable or thermally curable. In some embodiments, coating 140 may be transparent and cured by UV radiation. In some embodiments, coating 140 provides good scratch and abrasion resistance and is sufficiently transparent to allow a print design to be visible from and through the topside of the product. In some embodiments, coating 140 comprises a UV curable polyurethane. In some embodiments, coating 140 comprises a moisture curable polyurethane. In some embodiments, coating 140 comprises an acrylate. In some embodiments, coating 140 comprises a polyurethane and an acrylate.

In some embodiments, coating 140 may comprise particles that enhance dimensional stability and/or scratch resistance. In some embodiments, the particles are selected from chalk, barium sulfate, slate powder, silica, kaolin, quartz powder, talc, lignin, powdered glass, aluminum oxide, and glass fibers.

In some embodiments, coating 140 may have a thickness that ranges from about 0.001 to 0.1 mm. In some embodiments coating 140 may have a thickness that ranges from about 0.01 to 0.07 mm. In some embodiments coating 140 may have a thickness that ranges from about 0.015 to 0.05 mm.

In some embodiments, carrier 110 enhances the mechanical integrity of the floor tile 100 by acting as a backbone to the overall surface covering. In some embodiments, carrier 110 may be partially or completely embedded in the first linoleum layer 120 near the bottom surface 102 of the linoleum core. Embedding the carrier 110 in the first linoleum layer 120 may contribute to improving the dimensional stability of the floor tile 100 in some embodiments.

In some embodiments, carrier 110 may include a binder and a fibrous material. In some embodiments, the fibrous material is woven or knitted. In some embodiments, the binder may be present in an amount ranging from about 0 wt. % to about 40 wt. %, based on the weight of carrier 110. In other embodiments, the binder may be present in an amount ranging from about 1 wt. % to about 30 wt. % based on the weight of carrier 110.

According to some embodiments, the fibrous material may be selected from a synthetic fiber, a cellulosic fiber, a natural fiber, a synthetic fabric, and a combination of two or more thereof.

In some embodiments, the synthetic fiber may be selected from a polyester (e.g. polyethylene terepthalate), a polyolefin (e.g. polypropylene), polytetrafluoroethylene, polyacrlyonitrile, a polyamide (e.g. nylon), polyacrylate, fiberglass, etc., and a combination of two or more thereof. In some embodiments, the cellulosic fiber and natural fiber may be selected from cotton, jute, viscose, kraft paper, rayon, sisal, and a combination of two or more thereof. Some embodiments provide that the carrier may comprise a material selected from: jute fabric; a mixed fabric of natural fibers; carbon fibers; aramid fibers; quartz fibers; alumina fibers; silicon carbide fibers; and a combination of two or more thereof.

In some embodiments, the carrier comprises polyethylene terephthalate. In some embodiments, the carrier comprises polyethylene terephthalate and fiberglass.

In some embodiments, the binder may comprise a thermoplastic resin or a thermoset resin that is selected from, epoxies, polyurethanes, acrylic latex, phenolic resin, polyvinyl alcohol, carbohydrate polymers (i.e. starch), a cellulosic resin, a polyacrylamide, urea-formaldehyde, a melamine resin (e.g. melamine-formaldehyde, melamine-phenol-formaldehyde copolymer), an acrylic copolymer, styrene butadiene rubber, and a combination of two or more thereof. In some embodiments the binders may include one or more resins derived from the following monomers vinyl acetate, vinyl propionate, vinyl butyrate, vinyl chloride, vinylidine chloride, vinyl fluoride, vinylidene fluoride, ethyl acrylate, methyl acrylate, propyl acrylate, butyl acrylate, ethyl methacrylate, methyl methacrylate, butyl methacrylate, hydroxyethyl methylacrylate, styrene, butadiene, urethane, epoxy, melamine, and an ester.

In some embodiments, the peripheral edge surfaces 103 may be undercut and disposed at an inward angle A1 measured from the top edge 104 between 0 and 90 degrees to a vertical reference plane intersecting top edge 104 and extending perpendicular to the top and bottom major surfaces 101, 102, as shown in FIG. 2. The vertical reference plane is parallel to centerline CL of the floor tile 100. Peripheral edge surfaces 103 may be planar and form an acute angle A2 with respect to the top major surface 101 and an obtuse angle A3 with respect to the bottom major surface 102. Each peripheral edge surface 103 is therefore oblique to the top and bottom major surfaces of floor tile 100.

In some embodiments, angle A1 may be from about 2 degrees to about 75 degrees, alternatively from about 5 degrees to about 45 degrees, and alternatively in certain embodiments from about 10 degrees to about 20 degrees. The undercut profile forms a top major surface 101 which is greater in width W and length L (measured between the top peripheral edges 104 along the horizontal plane defined by the top major surface) than the width W and length L of the bottom major surface 102 (measured between bottom peripheral edges 105 along the horizontal plane defined by the bottom major surface). Accordingly, the peripheral edge surfaces 103 slope inwards towards the centerline CL of the tile going from the top major surface 101 of the tile 100 to the bottom major surface 102 such that the bottom edge 105 is inwardly offset from the top edge 104 with respect to centerline CL of the tile.

With continuing reference to FIG. 2, the perimeter gap 106 may have a substantially triangular shape in cross section with base of the triangle being formed by the support base or underlayment (e.g. subfloor) on which the floor tile 100 is placed. The gap 106 is therefore widest adjacent the bottom edge 105 of the tile 100 at the base-to-tile interface than at the top edge 104 which forms an upper apex of the gap. When two tiles 100 are placed in edge-to-edge abutting contact, the triangular cross section formed by the mating gaps 106 of each tile form an isosceles triangle in cases where each tile has a substantially similar peripheral edge surface 103 profile (allowing for tolerances in cutting or filing the tile edges to shape).

In some embodiments, all peripheral edge surfaces 103 may be angled so that the tile 100 has an undercut edge profile on all four MD and AMD edges. In some embodiments, the angles A1 may be identical on all four sides providing four isotropic tile edges in cross sectional profile. In other embodiments, the angles A1 may be different. In certain embodiments, the angles A1 may be identical on the opposing MD sides of the tile and the angles A1 may be identical on the AMD sides of the tile but different than the MD side angle. Numerous variations are possible.

In some embodiments, the peripheral edge surfaces 103 of tile 100 are sealed to minimize moisture absorption by the tile, which might cause distortion and contribute to curling or doming. In some embodiments, a polymeric seal coat or sealant such as without limitation polyurethane may be applied to the cut tile MD and AMD peripheral edge surfaces 103 to serve as moisture barrier. Other suitable polymeric coatings may be used for this purpose.

According to another aspect of the invention, unidirectional tile layout may be produced using non-square tiles. In some embodiments, using rectangular or plank-shaped tiles, machine direction (MD) peripheral edge surfaces are directly abutted against across machine direction (AMD) peripheral edge surfaces. Significantly, MD edges of two adjoining tiles may be directly abutted. Advantageously, this allows creation of a wide variety of possible floor patterns not heretofore achievable with linoleum tiles that could only be laid with AMD-MD edge contact for masking dimensional stability differences. In addition, a combination of non-square tiles (e.g. rectangular) may be mixed with square tiles in a single flooring system without regard for which peripheral edge surfaces (MD or AMD) abut each other in the layout. This is possible due to the improvement in dimensional stability attributable to isotropic peripheral edge surface profiles, angled peripheral edge surface profiles, and/or tile size.

As shown in FIG. 7, a unidirectional tile layout may also be produced using square tiles 100 in which MD edges can directly contact MD edges of adjoining tiles, or AMD edges can directly contact AMD edges of adjoining tiles without concern. This is attributable, at least in part, to the tiles 100 according to the present disclosure having isotropic edge profiles. The directional arrows show the MD and AMD direction and illustrate the tile orientation and layout possible. In the layout shown, a combination of AMD-MD edge contact and AMD-AMD/MD-MD edge contact is possible (emphasized by dashed arrows in which an AMD edge of one tile abuts an AMD edge of another and MD edge of one tile abuts MD edge of another). The direction of the tiles 100 laid may therefore be random.

An exemplary method for installing floor tiles according to the present invention may include providing a plurality of floor tiles 100. In some embodiments, the floor tiles comprise linoleum. Floor tiles 100 each include an opposing pair of peripheral edge surfaces extending parallel to the machine direction (e.g. MD edges) and an opposing pair of peripheral edge surfaces extending parallel to the across machine direction (e.g. AMD edges).

The method continues with placing a first floor tile 100 on a support base that supports the tile and may be at any orientation including horizontal, vertical, and/or angled. A second floor tile 100 is then placed on the support base. An MD edge of the second floor tile is then abutted against an AMD edge of the first floor tile. A third floor tile 100 may then be placed on the support base. An MD edge of the third floor tile is then abutted against an AMD edge of the second floor tile.

Because the tiles 100 have isotropic edges, like MD edges and like AMD edges may alternatively be abutted against each other. Accordingly, in certain embodiments and variations of the method, an AMD edge of the second floor tile 100 may be abutted against an AMD edge of the first floor tile 100 (see, e.g. FIG. 7 showing tile with dashed arrow in which an AMD edge of one abuts an AMD edge of another). A MD edge of the third floor tile 100 may be abutted against a MD edge of the second floor tile, or optionally an AMD edge of the third floor tile may be abutted against the MD edge of the second floor tile.

It will be appreciated that the foregoing method may be used with square or non-square tiles, and combinations thereof.

Advantageously, floor tile 100 and corresponding flooring systems described herein remove the restrictions for installing floors and shapes of tile which can be utilized.

The invention will be described in greater detail by way of a specific example. The following example is offered for illustrative purposes and is not intended to limit the invention in any manner.

Example

Dimensional stability tests are conducted to compare 48 cm (18 inch) square tiles versus 30.5 cm (12 inch) square tiles, the results of which are shown below in Table 1.

TABLE 1
Tile Size (cm)	MD DS (%)	AMD DS (%)
48	0.03	0.09
48	0.03	0.09
48	0.04	0.10
48	0.04	0.07
30.5	0.08	0.13
30.5	0.08	0.15
30.5	0.08	0.15
30.5	0.08	0.15
30.5	0.09	0.16
30.5	0.08	0.13

As described in Table 1 (above), 48 cm (18 inch) square tiles unexpectedly provide greater AMD dimensional stability than 30.5 cm (12 inch) square tiles.

While the foregoing description and drawings represent exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods/processes described herein may be made within the scope of the present disclosure. One skilled in the art will further appreciate that the embodiments may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the disclosure, which are particularly adapted to specific environments and operative requirements without departing from the principles described herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive. The appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents.

Claims

1. A surface covering comprising: wherein the first surface area and the second surface area are different.

a linoleum core;

a first major surface terminating at a first edge, a second major surface terminating at a second edge, and a peripheral edge surface extending between the first and second edges;

the first major surface being arranged parallel to the second major surface;

the first major surface defining a first surface area;

the second major surface defining a second surface area; and

a carrier adjacent the linoleum core;

2. The surface covering according to claim 1, wherein the peripheral edge surface is planar and oriented obliquely to the top major surface and the bottom major surface.

3. The surface covering according to claim 2, wherein the peripheral edge surface is disposed at an angle from about 2 degrees to about 75 degrees with respect to a vertical reference plane that intersects the top major surface.

4. The surface covering according to claim 3, wherein the angle is from about 10 degrees to about 20 degrees.

5. The surface covering according to claim 1, wherein: wherein the first surface area is larger than the second surface area.

the first major surface is a top surface defining the first surface area and the first edge; and

the second major surface is a bottom surface for placement on a support base,

the bottom surface defining the second surface area and the second edge;

6. The surface covering according to claim 5, wherein the first edge is spaced at a greater horizontal distance from a centerline of the surface covering than the second edge.

7. The surface covering according to claim 1, wherein the peripheral edge is sealed with a polyurethane sealant.

8. The surface covering according to claim 1, wherein the linoleum core comprises a first linoleum layer and a second linoleum layer.

9. The surface covering according to claim 1, further comprising a coating disposed on the first major surface.

10. The surface covering according to claim 1, wherein the peripheral edge surface is at an acute angle with the first major surface and an obtuse angle with the second major surface.

11. The surface covering according to claim 1, wherein the surface covering comprises a plurality of isotropic peripheral edge surfaces each having a substantially identical edge profile in cross sectional view.

12. A floor covering system comprising:

a plurality of floor tiles arranged edge-to-edge on a support base, each tile comprising: a linoleum core comprising a first linoleum layer and a second linoleum layer; a top major surface terminating at a top edge; a bottom major surface terminating at a bottom edge; and a peripheral edge surface extending between the top and bottom edges; and a carrier; wherein the peripheral edge surface is planar and oriented obliquely to the top and bottom major surfaces; and wherein a gap formed between the peripheral edge surfaces of adjoining tiles, has a greater width between the bottom edges of adjoining tiles than at the top edges.

13. The flooring covering system according to claim 12, wherein the gap has a substantially triangular cross section.

14. The floor covering system according to claim 13, wherein the triangular cross section is in the form of an isosceles triangle formed by the gaps of adjoining tiles.

15. The surface covering system according to claim 12, wherein the peripheral edge surface is disposed at an angle from about 2 degrees to about 75 degrees with respect to a vertical reference plane that intersects the top major surface.

16. The floor covering system according to claim 15, wherein the angle is from about 10 degrees to about 20 degrees.

17. A floor tile comprising:

a linoleum core comprising a first linoleum layer and a second linoleum layer;

a polymeric wear layer disposed on the linoleum core;

a carrier embedded in the first linoleum layer;

a top major surface terminating at a plurality of top edges, a bottom major surface terminating at a plurality of bottom edges, and a plurality of peripheral edge surfaces extending between the top and bottom edges around a perimeter of the tile;

the top major surface being arranged parallel to the bottom major surface;

the wear layer defining the top major surface;

the first linoleum layer defining the bottom major surface; and

wherein the top major surface has a first area and the bottom major surface has a second area, the second area being less than the first area.

18. The floor tile according to claim 17, wherein the peripheral edge surfaces are each at an acute angle with the top major surface and an obtuse angle with the bottom major surface.

19. The floor tile according to claim 17 or claim 18, wherein each peripheral edge surface is disposed at an angle from about 10 degrees to about 20 degrees with respect to a vertical reference plane oriented parallel to a centerline of the tile.

20. The floor tile according to claim 17, wherein the first linoleum layer comprises a first linoleum composition and the second linoleum layer comprises a second linoleum composition.