Resilient floor tile and method for making same
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 decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. In another embodiment, the resilient floor tile comprises an imprint having a predetermined pattern in a top surface of the floor tile that allows the floor tile to be separated along the imprint into smaller floor tiles. The process for making a resilient floor tile according to the various embodiments is described.
1 . A process for making a resilient floor tile, comprising:
preheating a printed tile blank;
cutting said printed tile blank; and
molding said printed tile blank to form a convex edge along a top, outer perimeter of said printed tile blank;
wherein said cutting and molding are performed concurrently to form a resilient floor tile.
2 . The process of claim 1 , wherein said preheating comprises heating said printed tile blank to a temperature of approximately 100-200° F. to sufficiently soften said printed tile blank.
3 . The process of claim 2 , wherein said heating comprises heating said printed tile blank to a temperature of approximately 125-135° F.
4 . The process of claim 1 , further comprising repeating said preheating, said cutting, and said molding for a second printed tile blank.
5 . The process of claim 1 , wherein said preheating comprises conveying said printed tile blank through an oven; said cutting and molding comprise cutting and molding in a press; and further comprising:
destacking said printed tile blank prior to said preheating;
conveying said printed tile blank from the oven to a press;
ejecting said resilient floor tile and a frame from the press;
conveying said frame to a waste bin; and
conveying said resilient floor tile to a counter-stacker.
6 . The process of claim 1 , wherein said printed tile blank is uncoated and further comprising coating said printed tile blank to form a top coat after said cutting and said molding with a thermoset coating.
7 . A process for making a resilient floor tile, comprising:
means for softening a printed tile blank;
means for forming a resilient floor tile having a convex edge along an outer perimeter of said resilient floor tile from said printed tile blank.
8 . A process for making a resilient floor tile, comprising:
preheating a printed tile blank;
cutting said printed tile blank; and
molding said printed tile blank to form a convex edge along a top, outer perimeter of said printed tile blank and an imprint having a predetermined pattern in a top surface of said tile blank;
wherein said cutting and molding are performed concurrently to form a resilient floor tile.
9 . The process of claim 8 , wherein said preheating comprises heating said printed tile blank to a temperature of approximately 100-200° F. to sufficiently soften said printed tile blank.
10 . The process of claim 9 , wherein said heating comprises heating said printed tile blank to a temperature of approximately 125-135° F.
11 . The process of claim 8 , where said molding further comprises forming a convex edge along said imprint.
12 . The process of claim 8 , further comprising repeating said preheating, said cutting, and said molding for a second printed tile blank.
13 . The process of claim 8 , wherein said preheating comprises conveying said printed tile blank through an oven; said cutting and molding comprise cutting and molding in a press; and further comprising:
destacking said printed tile blank prior to said preheating;
conveying said printed tile blank from the oven to a press;
ejecting said resilient floor tile and a frame from the press;
conveying said frame to a recycle bin; and
conveying said resilient floor tile to a counter-stacker.
14 . The process of claim 8 , wherein said printed tile blank is uncoated and further comprising coating said printed tile blank to form a top coat after said cutting and said molding with a thermoset coating.
15 . A process for making a resilient floor tile, comprising:
means for softening a printed tile blank;
means for forming a resilient floor tile having a convex edge along an outer perimeter of said resilient floor tile and an imprint having a predetermined pattern in a top surface of said resilient floor tile from said printed tile blank.