AU2015328714A1 - Linoleum based flooring with edge detail - Google Patents

Abstract

Described herein are surface coverings comprising: a linoleum core; a top major surface having a first length and a first width, the top major surface terminating at a first edge; a bottom major surface having a second length and a second width, the bottom major surface terminating at a second edge; and a peripheral edge surface extending between the first and second edges, the peripheral edge surface being planar and oriented obliquely to the top and bottom major surfaces; wherein at least one of the first length or first width is smaller than the second length or second width respectively. Methods of making and using these surface coverings are also described.

Description

PCT/US2015/031284 WO 2016/057082

LINOLEUM BASED FLOORING WITH EDGE DETAIL CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a PCT International Application that claims the benefit of United States Provisional Patent Application No. 62/062,536 filed on October 10, 2014. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE DISCLOSURE

[0001] The present disclosure relates to surface coverings, and more particularly to linoleum based floor tiles having edge detail.

BACKGROUND

[0002] The ability of a floor covering product to remain substantially flat under varying environmental conditions is desirable. Dimensional stability (DS) is one applicable measure of floor coverings 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.

[0003] 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 - 1 - PCT/US2015/031284 WO 2016/057082 and relatively close in value as possible which is indicative of DS uniformity of the flooring product and resistance to curling and doming.

[0004] 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. To compensate for these differences in dimensional stability, every other tile is rotated 90 degrees (“quarter turning”) during installation (see, e.g. FIG. 1) so that no MD edge (i.e. edges parallel to the machine direction) directly contacts an AMD edge (i.e. edges parallel to the across machine direction) of an adjacent tile.

[0005] The foregoing quarter turn installation method does not allow for unidirectional installation where like MD and AMD edges can be disposed and directly abutted against each other. Accordingly, only square tiles can generally be used so every MD edge contacts an AMD edge after quarter turning so no like edge details meet in the installed floor. Unfortunately, this severely limits the patterns which may be created with linoleum tiles.

[0006] Embodiments of the present invention are designed to overcome the aforementioned issues.

SUMMARY

[0007] 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 tile may comprise isotropic edges (i.e. 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.

[0008] Advantageously, the present invention allows unidirectional installation of tiles so that MD edges may be directly abutted against MD edges, and AMD edges may be directly abutted against AMD edges without detriment. Quarter turning tiles for installation is therefore not required. 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 patterns because like MD-MD edges and/or like AMD-AMD edges may be in direct contact without adversely affecting dimensional stability. Heretofore, tile shapes in which MD and AMD edges must be directly abutted to each other in the floor layout were unobtainable. Tiles according to the present disclosure therefore allow a wide variety of floor patterns to be formed using non-square tiles, such as without limitation a herringbone, a subway or running -2- PCT/US2015/031284 WO 2016/057082 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.

[0009] In some embodiments, a surface covering includes: a linoleum core; a top major surface having a first length and a first width, the top major surface terminating at a first edge; a bottom major surface having a second length and a second width, the bottom major surface terminating at a second edge; and a peripheral edge surface extending between the first and second edges, the peripheral edge surface being planar and oriented obliquely to the top and bottom major surfaces; wherein at least one of the first length or first width is less than the second length or second width respectively.

[0010] 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.

[0011] In other embodiments, a surface covering includes: 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; the top major surface being arranged parallel to the bottom major surface; the top major surface defining a first surface area; the bottom major surface defining a second surface area; and a carrier, wherein the second surface area is greater than the first surface area. In some embodiments, the carrier is embedded at least partially in the linoleum core.

[0012] Further embodiments provide 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; wherein the peripheral edge surface is planar and oriented obliquely to the top and bottom major surfaces. In some embodiments, a gap is formed between adjoining tiles between the peripheral edge surfaces of the tiles, the gap having a greater width between the top edges of adjoining tiles than at the bottom edges.

[0013] Still further embodiments provide a floor tile comprising: a linoleum core; a wear layer disposed on the linoleum core; a top major surface terminating at a plurality of top -3- PCT/US2015/031284 WO 2016/057082 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; and a carrier.

[0014] In some embodiments, wherein the linoleum core comprises a first linoleum layer and a second linoleum layer, the carrier is embedded, at least partially in the first linoleum layer.

[0015] In some embodiments, the carrier is completely embedded in the first linoleum layer. In those embodiments wherein the carrier is completely embedded in the first linoleum layer, the first linoleum layer defines the bottom major surface. In some embodiments, the top major surface has a first area and the bottom major surface has a second area, the second area being greater than the first area.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 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: [0017] FIG. 1 is a top plan view of a prior art quarter turned flooring system; [0018] FIG. 2 is a side elevation cross-sectional view of a floor tile for use in a flooring system according to the present disclosure; [0019] FIG. 3 is an exploded view thereof; [0020] 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; [0021] 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; [0022] FIG. 6 is a top plan view of an exemplary carrier of the present invention; [0023] FIG. 7 is an exemplary flooring system with a pattern formed by using exemplary square tiles of the present invention; and [0024] FIG. 8 is a side view of two adjoining abutting floor tiles of the preset invention placed on a common support base.

[0025] 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. -4- PCT/US2015/031284 WO 2016/057082

DFTATT F.D DESCRIPTION

[0026] 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.

[0027] 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.

[0028] 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.

[0029] FIGS. 2-5 depict non-limiting exemplary embodiments of a surface covering product such as without limitation a floor tile 100 in accordance with principles of the present invention. Floor tiles 100 may be used for forming a flooring system comprised of a plurality of tiles laid with abutting joints between tiles. In some embodiments, floor tile 100 may be a linoleum tile. The terms “flooring tile” and “product” are used herein for convenience of description only, and are intended to encompass surface coverings that may be applied to any -5- PCT/US2015/031284 WO 2016/057082 suitable type and oriented surface including without limitation horizontal, vertical, and/or angled or sloped surfaces. Application surfaces or substrates to which the products described herein are 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.

[0030] 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 on the second linoleum layer 130. In some embodiments, a single homogenous linoleum core 151 may be provided in lieu of a composite structure having a plurality of linoleum layers.

[0031] 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 be placed adjacent a suitable support base or underlayment. In the case of a flooring system, the support base may be a subfloor.

[0032] 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.

[0033] In one non-limiting exemplary embodiment, the length and/or width of the top major surface 101 of tile 100 is less than the corresponding length and/or width of the bottom major surface 102 respectively. In another non-limiting exemplary embodiment, in which tile 100 has isotropic edges (i.e. all the same edge profile), both the length and width of the top major surface 101 of tile 100 are less than the corresponding length and width of the bottom major surface 102 respectively. In either of the foregoing exemplary embodiments, the surface area defined by the top major surface 101 is less than the surface area defined by the bottom major surface 102. Accordingly, in either of the foregoing exemplary embodiments, the peripheral -6- PCT/US2015/031284 WO 2016/057082 edge surfaces 103 have an “overcut” configuration where the bottom edge 105 of the tile protrudes laterally beyond the top edge 104 (see, e.g. FIGS. 2 and 3).

[0034] Any suitable thickness of tile 100 may be used. Some embodiments provide that the overall thickness of tile 100 may be varied, e.g. about 2 mm being used for lighter wear applications and greater thicknesses such as about 2.5 mm and about 3.2 mm being used for more critical applications. However, in general, some embodiments provide that tile 100 can have an overall thickness of from about 1 mm to about 6 mm; alternatively from about 1.5 mm to about 4 mm.

[0035] 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. In 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 0.5 pm to about 20pm. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 pm to about 10 pm. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 pm to about 5 pm.

[0040] Some embodiments provide that the first and/or second 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, -7- PCT/US2015/031284 WO 2016/057082 dolomite, wollastonite, ealcite, pigments, zinc oxide, zinc sulfate, or a combination of two or more thereof.

[0041] 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.

[0042] 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.

[0043] 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: < 160pm: 40-90%, and < 80pm 10-50%. In other embodiments, the wood flour comprises particles having a particle size distribution as follows: < 160pm 50 - 85%; and < 80pm 10-30%.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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 PCT/US2015/031284 WO 2016/057082 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.

[0048] 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.

[0049] 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.

[0050] 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 second linoleum layer 130 may be greater than the thickness of the first linoleum layer 120.

[0051] 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 layer. 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 -9- PCT/U S2015/031284 WO 2016/057082 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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. - 10- PCT/US2015/031284 WO 2016/057082 [0058] In some embodiments, the carrier comprises polyethylene terephthalate. In some embodiments, the carrier comprises polyethylene terephthalate and fiberglass.

[0059] 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.

[0060] According to one aspect of the invention, the peripheral edge surfaces 103 may be overcut and sloped outwards going from the top major surface 101 to the bottom major surface 102. Edge surfaces 103 are disposed at an angle A1 measured from the tile bottom edge 105 between 0 and 90 degrees to a vertical reference plane intersecting bottom edge 105 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 floor tile 100. Peripheral edge surfaces 103 may be planar and form an obtuse angle A2 with respect to the top major surface 101 and an acute 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.

[0061] In some exemplary embodiments, without limitation, angle A1 may be from about 5 degrees to about 30 degrees, and alternatively in certain embodiments from about 10 degrees to about 20 degrees. In other embodiments, the overcut profile forms a top major surface 101 which is smaller 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 outward 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 top edge 104 is inwardly offset from the bottom edge 105 with respect to centerline CL of the tile. - 11 - PCT/US2015/031284 WO 2016/057082 [0062] Without intending to be bound by theory, the present inventors believe that overcutting the peripheral edge surfaces 103 of tile 100 improves the dimensional stability of tile 100 by creating free volume defined by a gap or space 106 proximate to the top peripheral edges 104 around the top perimeter of the tile 100 which allows for expansion under high relative humidity conditions. Advantageously, this allows MD and AMD edges to be directly abutted during installation, permitting the use of non-square tiles that can create a wide variety of patterns.

[0063] With continuing reference to FIG. 2, the perimeter gap 106 may have a substantially triangular shape in cross section with the base of the triangle being formed adjacent the top edge 104 of tile 100 and the pointed tip by the support base or underlayment (e.g. subfloor) on which the floor tile is placed. The gap 106 is therefore widest adjacent the top edge 104 of the 100. The bottom apex of the gap therefore is disposed at the base-to-tile interface at the tile bottom edge 105. 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 forms 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).

[0064] In some embodiments, all peripheral edge surfaces 103 may be angled so that the tile 100 has an overcut edge profile on all four peripheral edge surfaces. 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.

[0065] In another aspect, the inventors have determined that sealing the peripheral edge surfaces 103 of tile 100 after cutting and/or filing the tile edges will act to minimize moisture absorption by the tile which might cause distortion and contribute to curling or doming. In one embodiment, 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.

[0066] According to another aspect of the invention, unidirectional tile layout may be produced using non-square tiles 100. As shown in the exemplary partial flooring layout in FIG. 7, using rectangular or plank-shaped tiles 100, machine direction peripheral edge surfaces 103 MD are directly abutted against across machine direction peripheral edge surfaces 103 AMD. Significantly, MD edges of two adjoining tiles may be directly abutted - 12- PCT/US2015/031284 WO 2016/057082 as illustrated. 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 100 (e.g. rectangular) may be mixed with square tiles 100’ (shown dashed) in a single flooring system as illustrated without quarter turning or regard for which peripheral edge surfaces 103 MD or AMD abut each other in the layout. This is possible due to more uniform dimensional stability provided by overcut isotropic peripheral edge surface profiles of tiles 100.

[0067] As shown in FIG. 8, a unidirectional tile layout may therefore also be produced using square floor 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 to the tiles 100 according to the present disclosure having more uniform dimensional stability in the MD and AMD. Quarter turning tiles is therefore not required. FIG. 8 illustrates the tile orientation and layout possible, and the directional arrows show MD and AMD for a few tiles 100. 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 tile and the MD edge of one tile abuts the MD edge of another tile). The direction of the tiles 100 laid may therefore be random.

[0068] An exemplary method for installing floor tiles according to the present invention may include providing a plurality of floor tiles 100. In one embodiment, the floor tiles are linoleum tiles. In some embodiments, the 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).

[0069] The method continues with placing a first floor tile 100 on a support base of 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.

[0070] Because the tiles 100 have isotropic edges which do not require quarter turning during installation, like MD edges and like AMD edges may be abutted against each other on the support base. Accordingly, in certain embodiments and variations of the method, an AMD - 13- PCT/US2015/031284 WO 2016/057082 edge of the second floor tile 100 may be abutted against an AMD edge of the first floor tile 100 (see, e.g. FIG. 8 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.

[0071] It will be appreciated that the foregoing method may be used with square or nonsquare tiles and combinations thereof.

[0072] Advantageously, the floor tiles 100 and corresponding flooring systems described herein remove the restrictions for installing floors and shapes of tile which can be utilized due to improved dimensional stability.

EXAMPLE

[0073] The dimensional stability of exemplary surface coverings of the present invention is evaluated against the dimensional stability of comparative surface coverings at a temperature of 25 °C and 80% relative humidity (RH). Table 1 (below) describes the results of these evaluations. Specifically, the dimensional stability values provided for Example I (Ex. I) represent the average dimensional stability demonstrated by four (4) surface coverings having a ten degree (10°) overcut edge profile on the peripheral surfaces; and the dimensional stability values provided for Comparative Example I (Comp. Ex. I) represent the average dimensional stability demonstrated by four (4) surface coverings having a ten degree (10°) undercut edge profile on the peripheral surfaces. Similarly, the dimensional stability values provided for Example II (Ex. II) represent the average dimensional stability demonstrated by three (3) surface coverings having a ten degree (10°) overcut edge profile on the peripheral surfaces; and the dimensional stability values provided for Comparative Example II (Comp. Ex. II) represent the average dimensional stability demonstrated by three (3) surface coverings having a ten degree (10°) undercut edge profile on the peripheral surfaces. The composition and structure of all of the surface coverings evaluated, aside from the peripheral edge surface profiles, are identical.

Table 1

Example Scrim Dimensional Stability (%) Machine Direction Across Machine Direction Ex. I Glass/PET 0.06 0.07 Comp. Ex. I Glass/PET 0.08 0.11 - 14- PCT/US2015/031284

Ex. II PET/PET 0.09 0.10 Comp. Ex. II PET/PET 0.09 0.15 WO 2016/057082 [0074] As demonstrated by the data described in Table 1 (above), exemplary surface coverings of the present invention having an “overcut” peripheral edge surface profile provide more uniform MD and AMD dimensional stability than the comparative surface coverings which do not include an “overcut” peripheral edge surface profile. The greater uniformity in MD and AMD dimensional stability is evidenced by the lesser difference in MD and AMD dimensional stability exhibited by the surface coverings of the present invention.

[0075] 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. -15-

Claims (22)

1. A surface covering comprising: a linoleum core; a top major surface having a first length and a first width, the top major surface terminating at a first edge; a bottom major surface having a second length and a second width, the bottom major surface terminating at a second edge; and a peripheral edge surface extending between the first and second edges, the peripheral edge surface being planar and oriented obliquely to the top and bottom major surfaces; wherein at least one of the first length or first width is smaller than the second length or second width respectively.

2. The surface covering according to claim 1, wherein the top major surface has a smaller surface area than the bottom major surface.

3. The surface covering according to claim 1, wherein the peripheral edge surface is disposed at an angle from about 5 degrees to about 30 degrees with respect to a vertical reference plane that intersects the second edge of the linoleum core.

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 any one of claims 1 to 4, wherein the linoleum core comprises a first linoleum layer and a second linoleum layer.

6. The surface covering according to claim 5, further comprising a coating disposed on the second linoleum layer.

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

8. 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.

9. A surface covering 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; the top major surface being arranged parallel to the bottom major surface; the top major surface defining a first surface area; the bottom major surface defining a second surface area; and a carrier embedded in the first linoleum layer; wherein the second surface area is greater than the first surface area.

10. The surface covering according to claim 9, wherein the peripheral edge surface is planar and oriented obliquely to the first major surface and the second major surface.

11. The surface covering according to claim 10, wherein the peripheral edge surface is disposed at an angle from about 5 degrees to about 30 degrees with respect to a vertical reference plane that intersects the bottom edge of the linoleum core.

12. The surface covering according to claim 11, wherein the angle is from about 10 degrees to about 20 degrees.

13. The surface covering according to claim 12, wherein the bottom edge is spaced at a greater horizontal distance from a centerline of the surface covering than the top edge.

14. The surface covering according to any one of claims 9 to 13, wherein the peripheral edge surface is sealed with a sealant.

15. 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 embedded at least partially in the first linoleum layer; wherein the peripheral edge surface is planar and oriented obliquely to the top and bottom major surfaces; a gap formed between adjacent tiles between the peripheral edge surfaces of the tiles, the gap having a greater width between the top edges of adjacent tiles than at the bottom edges.

16. The flooring covering system according to claim 15, wherein the gap has a substantially triangular cross section.

17. The floor covering system according to claim 16, wherein the triangular cross section is in the form of an isosceles triangle formed by the gaps of adjacent tiles.

18. The floor covering system according to any one of claims 15 to 17, wherein the peripheral edge surface is disposed at an angle from about 5 degrees to about 30 degrees with respect to a vertical reference plane that intersects the first edge of the linoleum core.

19. The floor covering system according to claim 18, wherein the angle is from about 10 degrees to about 20 degrees.

20. A floor tile comprising: a linoleum core comprising a first linoleum layer and a second linoleum layer; a carrier embedded at least partially in the first linoleum layer; a polymeric wear layer disposed on the second 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; wherein the top major surface has a first area and the bottom major surface has a second area, the second area being larger than the first area.

21. The floor tile according to claim 20, wherein the peripheral edge surfaces are each at an obtuse angle with the top major surface and an acute angle with the bottom major surface.

22. The floor tile according to claim 21, 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.