Nonwoven surface covering element with tongue and groove

Abstract

A surface covering element may have a rigid core. The rigid core may include at least one dense fiber mat. The rigid core may have a first surface and an opposing second surface spaced apart along a first axis. The rigid core may have a plurality of edges defining an outer periphery of the rigid core. The plurality of edges may include at least a first edge and an opposing second edge spaced apart along a second axis perpendicular to the first axis. The first edge may include a tongue, and the second edge may define a groove.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 63 / 419,166, filed Oct. 25, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This application generally relates to surface coverings, and more particularly to surface covering elements including nonwoven materials, the surface covering elements having tongues and grooves. Background Art

[0004] Fiberboards, particularly medium density fiberboards and high density fiberboards, and plastic materials such as PVC resins or other solid thermoplastic or thermosetting polymers are commonly used as core backing materials for floor coverings, wall coverings, and ceiling panels. For example, some existing floor panels typically consist of a particleboard core such as a medium density fiberboard (MDF) or high density fiberboard (HDF) core or a PVC core, which are covered (laminated) with a decorative layer and a wear surface or finish layer.

[0005] Laminate flooring has also proven to be a visually appealing, cost-effective, relatively lightweight flooring material that can also be installed by non-professionals. In addition, these laminate floorings are correspondingly widely promoted. However, these laminate floorings typically have relatively high impact noise, low radiant panel ratings, and high environmental impacts.

[0006] There is still a need to obtain surface covering elements that do not require complex layer structures to obtain characteristics suitable for heavy-duty applications. Further still, there is a need to obtain surface covering elements that have one or more of high impact strength, resistance to thermal expansion, heat resistance, dimensional stability, acceptable radiant panel ratings, and improved acoustic performance such as sound transmission compared to existing fiberboards or composite boards. Further still, there is a need for a system for joining such surface covering elements together to form a surface covering. Summary of the Invention

[0007] Described herein in various aspects is a surface covering element that includes a rigid core. The rigid core includes at least one dense fiber mat. The rigid core has a first surface and an opposite second surface spaced apart along a first axis. The rigid core includes a plurality of edges defining an outer perimeter of the rigid core. The plurality of edges includes at least a first edge and an opposite second edge spaced apart along a second axis perpendicular to the first axis. The first edge includes a tongue, and the second edge may define a groove.

[0008] The present text also describes a surface covering which comprises a plurality of surface covering elements, including at least a first surface covering element and a second surface covering element. The tongue of the first surface covering element fits into the groove of the second surface covering element.

[0009] The present text also describes a method of assembling a surface covering, which comprises the following steps: assembling a plurality of surface covering elements, including at least a first surface covering element and a second surface covering element. The tongue of the first surface covering element is inserted into the groove of the second surface covering element.

[0010] The present text also describes a method of manufacturing a surface covering element, which comprises the following steps: forming a tongue along a first edge of a rigid core. The rigid core comprises at least one dense fiber mat which includes a first surface and an opposite second surface spaced apart along a first axis. The rigid core comprises a plurality of edges defining the outer perimeter of the rigid core, the plurality of edges including at least a first edge and an opposite second edge spaced apart along a second axis perpendicular to the first axis.

[0011] Additional advantages of the present invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the present invention. The advantages of the present invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. Description of the Drawings

[0012] These and other features of the preferred embodiments of the present invention will become more apparent in the detailed description with reference to the drawings, in which:

[0013] Figure 1 is a top view of an exemplary surface covering element disclosed herein.

[0014] Figure 2 is Figure 1 a cross-sectional view of the surface covering element taken along plane 2-2, and in which the central portion is removed to show end details.

[0015] Figure 3 is a schematic side view of the first surface covering element and the second surface covering element assembled together to form a surface covering.

[0016] Figure 4 is a schematic side view of the first surface covering element and the second surface covering element assembled together to form a surface covering.

[0017] Figure 5Is a schematic side view of a first surface covering element and a second surface covering element assembled together, wherein the first and second surface covering elements have tongues and grooves as disclosed herein.

[0018] Figure 6 Is a schematic view of a first and a second plurality of fiber felts forming a dense fiber felt.

[0019] Figure 7 Is a schematic top view of a surface covering including the surface covering element disclosed herein.

[0020] Figure 8 Is Figure 7 A schematic cross-sectional view of the surface covering of.

[0021] Figure 9 Is a close-up image of a first corner of an exemplary surface covering element disclosed herein.

[0022] Figure 10 Is a close-up image of a second corner of an exemplary surface covering element disclosed herein.

[0023] Figure 11 Is a close-up image of a third corner of an exemplary surface covering element disclosed herein.

[0024] Figure 12 Is a close-up image of a fourth corner of an exemplary surface covering element disclosed herein.

[0025] Figure 13 Is a perspective view of an exemplary section of adjacent rigid cores according to an embodiment disclosed herein.

[0026] Figure 14 Is Figure 13 The cross-sectional profile of the section of.

[0027] Figure 15 Is a perspective view of an exemplary section of adjacent rigid cores according to an embodiment disclosed herein.

[0028] Figure 16 Is Figure 15 The cross-sectional profile of the section of. Detailed Description

[0029] The disclosed systems and methods may be more readily understood by reference to the following detailed description of specific embodiments and the examples and figures included therein and their previous and subsequent descriptions.

[0030] Definitions

[0031] It should be understood that the terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the scope of the present invention, which will be limited only by the appended claims.

[0032] It must be noted that, as used herein and in the appended claims, the singular forms "a / an" and "the" may optionally include plural referents, unless the context clearly dictates otherwise. Thus, for example, unless the context dictates otherwise, a reference to "a layer" discloses the disclosure of embodiments providing only a single layer as well as embodiments providing a plurality of such layers.

[0033] "Optional" or "optionally" means that the subsequent described event, situation or material may or may not occur or exist, and the description includes the cases where the event, situation or material occurs or exists and the cases where it does not occur or exist.

[0034] In this document, ranges may be expressed as from "about" a particular value and / or to "about" another particular value. When expressing such a range, unless the context clearly dictates otherwise, the range from one particular value and / or to another particular value is also specifically contemplated and considered to be disclosed. Similarly, when a value is expressed as an approximation by use of the antecedent "about", it should be understood that, unless the context specifically dictates otherwise, the particular value forms another specifically contemplated embodiment that should be considered to be disclosed. It should be further understood that, unless the context specifically dictates otherwise, each endpoint of a range is significant relative to the other endpoint and independent of the other endpoint. Finally, it should be understood that, unless the context clearly dictates otherwise, all individual values and sub-ranges of values contained within a specifically disclosed range are also specifically contemplated and should be considered to be disclosed. The foregoing applies regardless of whether some or all of these embodiments are specifically disclosed in a particular instance.

[0035] Optionally, in some aspects, when a value is approximated by use of the antecedents "about", "substantially" or "generally", values within up to 20%, up to 15%, up to 10%, up to 5% or up to 1% (higher or lower) of the specifically stated value or characteristic may be included within the scope of these aspects. For example, the term "substantially" may in some aspects mean at least 80%, at least 85%, at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99% or 100% of the characteristic, component, composition or other condition that is substantially used to characterize or otherwise quantify a quantity.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed devices, systems, and methods belong. Although any devices, systems, and methods similar to or equivalent to those described herein may be used in the practice or testing of the devices, systems, and methods of the present invention, particularly useful methods, devices, systems, and materials are as described.

[0037] Throughout the detailed description and claims of this specification, the word "comprise" and variations of the word, such as "comprising" and "comprises", mean "including but not limited to", and are not intended to exclude, for example, other additives, components, integers, or steps. In particular, in a method stated to comprise one or more steps or operations, each step is specifically contemplated to include what is listed (unless the step includes a limiting term such as "consisting of"), which means that each step is not intended to exclude, for example, other additives, components, integers, or steps not listed in the step.

[0038] When referring in the specification and concluding claims to the number of parts by weight of a specific element or component in a composition or article, it represents the weight relationship between that element or component and any other element or component in that composition or article, expressed as parts by weight. Thus, in a composition or a selected portion of a composition containing 2 parts by weight of component X and 5 parts by weight of component Y, X and Y are present in a weight ratio of 2:5, and are present in that ratio regardless of whether other components are present in the composition.

[0039] Unless specifically stated to the contrary, the weight percentage of a component is based on the total weight of the formulation or composition containing the component.

[0040] As used herein, the term "fiber" includes fibers of extremely long or indefinite length (i.e., filaments) and fibers of short length (i.e., staple fibers). It should be further understood that the fibers described herein can be interpreted to include materials from both virgin and recycled sources. In certain aspects of the surface covering elements disclosed herein, the fibers include recycled materials, where the recycled materials include, but are not limited to, post-consumer or post-industrial materials or combinations thereof. In still other aspects, the fibers used in the surface covering elements disclosed herein include virgin materials.

[0041] As used herein, the term "oriented fiber" refers to the orientation of fibers in a fiber mat or fiber matrix.

[0042] The term "rigid core" refers to any composite material that includes a rigid core and is capable of withstanding heavy-duty applications (such as, for example, high foot traffic) without any significant deformation of the board. Further still, in various aspects of the present disclosure, a rigid surface covering element can be functionally defined as an element that, when the surface covering element abuts the underlying floor structure in a selected orientation, at least substantially prevents irregularities (such as undulations and curls) of the hard surface underlying floor structure from being exposed to the decorative layer portion.

[0043] As used herein, the term "polyester" refers to a class of polymers that contain ester functional groups in their main chain. The polyesters disclosed herein include naturally occurring chemicals (such as those naturally occurring in cutin of plant epidermis) and synthetic products produced by step-growth polymerization. Non-limiting examples of polyesters include any long-chain synthetic polymer that consists of at least 85 wt% esters of substituted aromatic dicarboxylic acids, including but not limited to substituted terephthalic acid units, p(-R-O-CO-C6H4-CO-O-) x and substituted hydroxy-benzoate units, p(-R-O-CO-C6H4-O) x . In certain instances, polyesters include polyethylene terephthalate (PET) homopolymers and copolymers, polytrimethylene terephthalate (PPT) homopolymers and copolymers, and polybutylene terephthalate (PBT) homopolymers and copolymers, etc., including homopolymers and copolymers containing comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, isophthalic acid, etc.

[0044] As used herein, the term "polyamide" is defined as any long-chain polymer in which the linking functional group is an amide (-CO-NH-) bond. The term polyamide is further defined to include copolymers, terpolymers, etc., as well as homopolymers, and also blends of two or more polyamides. In some aspects, the plurality of polyamide fibers include one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combination thereof. In other aspects, the plurality of polyamide fibers include nylon 6 or nylon 66. In still other aspects, the plurality of polyamide fibers are nylon 6. In yet further aspects, the plurality of polyamide fibers are nylon 66.

[0045] As defined herein, the term "polyolefin" refers to any type of polymer produced from simple olefins (also referred to as olefins having the general formula C n H 2n as monomers). In some aspects, polyolefins include but are not limited to polyethylene, polypropylene, whether homopolymers or copolymers, poly(1-butene), poly(3-methyl-1-butene), poly(4-methyl-1-pentene), etc., and combinations or mixtures of two or more of the foregoing.

[0046] As defined herein, the term "polyurethane" refers to any class of polymers consisting of a string of organic units joined by urethane (ethyl carbamate, R1-O-CO-NR2-R3, where R1, R2, and R3 are the same or different) bonds.

[0047] As used herein, the term "polystyrene" refers to any class of synthetic polymers produced from simple styrene as a monomer. It should be understood that the term "polystyrene" encompasses both atactic polystyrene and syndiotactic polystyrene. In some specific aspects, copolystyrenes are also described, including high impact polystyrene (HIPS), acrylonitrile-butadiene-styrene (ABS), or copolymers of styrene and acrylonitrile (SAN) or copolymers of styrene and maleic acid (SMA).

[0048] As defined herein, the term "acetal" refers to a functional group having the connectivity of R2C(OR ’ )2, where the two R ’ groups can include hydrogen or organic moieties. The two R ’ O groups can be equivalent to each other (referred to as a symmetric acetal) or different (referred to as a mixed acetal).

[0049] In other aspects, as used herein, when used in the context of a composition or a component of a composition that is substantially absent, the term "substantially free of" is intended to refer to an amount of the material that is less than about 1 wt%, such as less than about 0.5 wt%, less than about 0.1 wt%, less than about 0.05 wt%, or less than about 0.01 wt% based on the total weight of the composition.

[0050] As used herein, the term or phrase "effective", "effective amount", or "effective conditions" refers to such an amount or conditions that are capable of performing the function or property expressed as an effective amount or conditions. As will be pointed out below, the exact amount or specific conditions required will vary from one aspect to another depending on the identified variables (such as the materials employed and the processing conditions observed). Thus, it is not always possible to specify the exact "effective amount" or "effective conditions". However, it should be understood that one of ordinary skill in the art can readily determine the appropriate effective amount using only routine experimentation.

[0051] As used herein, and unless the context clearly indicates otherwise, the term "carpet" is generally used to include broadloom carpets, carpet tiles, rugs, and even artificial turf (or turf). For this purpose, the term "broadloom carpet" refers to a wide textile floor product manufactured in a roll form and intended to be used in a roll form. The term "carpet tile" refers to a modular floor covering conventionally manufactured in 18”×18”, 24”×24”, or 36”×36” squares, although other sizes and shapes are also within the scope of the surface covering elements disclosed herein. Any of these exemplary carpets can be woven, non-woven, tufted, or needle-punched.

[0052] As used herein, the term "reclaimed fiber" includes fibers reclaimed from new products, post-industrial products, manufacturing remnants, quality control rejects or discarded materials, or post-consumer products. In some exemplary aspects, such products include carpets or carpet tiles.

[0053] As used herein, the term "post-consumer fiber" refers to fibers that were part of a product previously used by a consumer. Post-consumer fibers include fibers reclaimed from products that have been used in residential, commercial, and industrial applications and have subsequently been collected from the place of use or otherwise discarded.

[0054] As used herein, the term "post-industrial fiber" refers to fibers reclaimed from products that are manufacturing by-products of products that have been diverted from the manufacturing waste stream.

[0055] As used herein, the term "acclimation period" refers to the period of time required to adjust or condition one or more components in a surface covering element to equalize the different stresses that may be present in the various components. In some aspects, the lack of an "acclimation period" can refer to the lack of an acclimation period associated with the assembly of the various components during the manufacture of the surface covering elements disclosed herein. In other aspects, the acclimation period can refer to the period of time or lack thereof between the product's arrival at the installation site and the actual installation of the product.

[0056] In addition to the locking elements provided by the surface covering element, an interlocking mechanism as defined herein can further include locking elements. In some instances, such locking elements can include strips having prominent features that engage the locking elements into two adjacent articles. Such locking devices can be made of the same materials as the surface covering element, aluminum, wood fiber, etc.

[0057] Although aspects of the surface covering elements disclosed herein may be described and claimed in specific statutory classes, such as system statutory classes, this is for convenience only, and one of ordinary skill in the art will understand that each aspect of the surface covering elements disclosed herein may be described and claimed in any statutory class. Unless otherwise expressly stated, no method or aspect set forth herein is intended to be construed as requiring that its steps be performed in a particular order. Accordingly, where method claims do not specifically recite steps as being limited to a particular order in the claims or specification, no order should be inferred in any aspect. This applies to any possible non-expressive basis for interpretation, including matters of logic with respect to step arrangement or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

[0058] The present invention can be more readily understood by reference to the following detailed description of various aspects of the invention and the examples contained therein, as well as by reference to the accompanying drawings and the description before and after them.

[0059] Exemplary surface covering element

[0060] Referring to Figure 1 and 2 , a surface covering element 10 as disclosed herein may include a rigid core 12 that includes at least one dense fiber mat 14. The rigid core 12 may include a first surface 16 and an opposing second surface 18 that are spaced apart along a first axis 4. The rigid core 12 may include a plurality of edges 20 that define an outer perimeter of the rigid core 12. The plurality of edges 20 may include at least a first edge 20a and an opposing second edge 20b that are spaced apart along a second axis 6 that is perpendicular to the first axis 4. The first edge 20a may include a tongue 22. The second edge 20b may define a groove 24.

[0061] In some aspects, the rigid core 12 may include a plurality of layers 26 of the dense fiber mat 14. For example, in some aspects, the plurality of layers 26 of the dense fiber mat 14 may include at least a first dense fiber mat 14a and a second dense fiber mat 14b. In some optional aspects, the first dense fiber mat 14a may have a first density, and the second dense fiber mat 14b may have a second density that is greater than the first density. It is contemplated that the greater second density of the second dense fiber mat 14b may provide rigidity to the rigid core. In this manner, the dense fiber mat having the greater second density may, for example, span an uneven floor and resist indentation. The dense fiber mat having the lower density of the first dense fiber mat 14a may provide mechanical absorption of the rigid core 12. In this manner, the first dense fiber mat may both reduce noise within the room in which the surface covering element is located and reduce airborne conduction through the surface (e.g., the floor) and into adjacent rooms.

[0062] In an exemplary aspect, the second density can be 40 lb / ft 3 to about 100 lb / ft 3 In an exemplary aspect, the first density can be 10 lb / ft 3 to 30 lb / ft 3 In a further aspect, the first density can be 5 lb / ft 3 to 100 lb / ft 3 or 5 lb / ft 3 to 30 lb / ft 3 In other aspects, the second density can be 5 lb / ft 3 to 100 lb / ft 3 or 30 lb / ft 3 to 100 lb / ft 3 75 lb / ft 3 to 120 lb / ft 3 or about 100 lb / ft 3 .

[0063] In some aspects, the first density can be about 5 lb / ft 3 to about 100 lb / ft 3 , including exemplary densities of 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115 or 120 lb / ft 3 In a still further aspect, the first density can be a value within any range derived from the above values, including, for example, a density of from about 15 to about 75 pounds per cubic foot. In a still further aspect, the first density can be at most 100 lb / ft 3 .

[0064] In some aspects, the second density can be about 5 lb / ft 3 to about 100 lb / ft 3 , including exemplary densities of 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115 or 120 lb / ft 3 In a still further aspect, the second density can be a value within any range derived from the above values, including, for example, a density of from about 15 to about 75 pounds per cubic foot.

[0065] In some aspects, the first density can be at least about 10 lb / ft 3 , including at least about 15 lb / ft 3 about 20 lb / ft3 、 Exemplary values of about 25 lb / ft 3 、 about 30 lb / ft 3 、 about 35 lb / ft 3 、 about 40 lb / ft 3 、 about 45 lb / ft 3 、 or about 50 lb / ft 3 In some aspects, the first density can be in a range between any two of the foregoing values.

[0066] In some aspects, the second density can be at least about 10 lb / ft 3 including at least about 15 lb / ft 3 、 about 20 lb / ft 3 、 about 25 lb / ft 3 、 about 30 lb / ft 3 、 about 35 lb / ft 3 、 about 40 lb / ft 3 、 about 45 lb / ft 3 、 or about 50 lb / ft 3 In some aspects, the second density can be in a range between any two of the foregoing values.

[0067] In still other aspects, the first density can be no greater than about 50 lb / ft 3 、 about 45 lb / ft 3 、 about 40 lb / ft 3 、 about 35 lb / ft 3 、 about 30 lb / ft 3 、 25 lb / ft 3 、 about 20 lb / ft 3 、 about 15 lb / ft 3 or about 10 lb / ft 3 It should be understood that the first density can be as low as the density of a fiber mat that includes substantially the same first plurality of fibers and substantially the same second plurality of fibers that have not undergone any densification process such as heating or pressing.

[0068] In still other aspects, the second density can be no greater than about 50 lb / ft 3 、 about 45 lb / ft 3 、 about 40 lb / ft 3 、 about 35 lb / ft 3 、 about 30 lb / ft 3 、 25 lb / ft 3 、 about 20 lb / ft 3, about 15 lb / ft 3 or about 10 lb / ft 3 . In some aspects, the second density can have a density within a range between any two of the foregoing values. It should be understood that the second density can be as low as the density of a fiber mat that includes substantially the same first plurality of fibers and substantially the same second plurality of fibers that have not been subjected to any densification process, such as heating or pressing.

[0069] In an exemplary aspect, the first density can be 10 lb / ft 3 to 30 lb / ft 3 , and the second density can be 40 lb / ft 3 to about 100 lb / ft 3 In an exemplary aspect, the first density can be 10 lb / ft 3 to 100 lb / ft 3 , and the second density can be 5 lb / ft 3 to 100 lb / ft 3 , or 30 lb / ft 3 to 100 lb / ft 3 , 75 lb / ft 3 to 120 lb / ft 3 , or about 100 lb / ft 3 In a further aspect, the first density can be 5 lb / ft 3 to 100 lb / ft 3 , or 5 lb / ft 3 to 30 lb / ft 3 , and the second density can be 40 lb / ft 3 to about 100 lb / ft 3 In other aspects, the first density can be 5 lb / ft 3 to 100 lb / ft 3 , or 5 lb / ft 3 to 30 lb / ft 3 , and the second density can be 5 lb / ft 3 to 100 lb / ft 3 , or 30 lb / ft 3 to 100 lb / ft 3 , 75 lb / ft 3 to 120 lb / ft 3 , or about 100 lb / ft 3 In some optional aspects, it is contemplated that at least one of the first density or the second density can be between 35 lb / ft 3 and 60 lb / ft 3within the range. In other optional aspects, it is contemplated that both the first density and the second density can be within 35 lb / ft 3 to 60 lb / ft 3 range.

[0070] In some optional aspects, the first dense fiber mat 14a and the second dense fiber mat 14b can be needled together. For example, before densification, one or more needles can be passed through the first and second fiber mats to entangle the fibers of the respective fiber mats.

[0071] In some optional aspects, the first dense fiber mat 14a can define a first surface 16 of the rigid core 12.

[0072] In an exemplary aspect and as Figure 2 shown, the second dense fiber mat 14b can define a tongue 22, and a plurality of portions of the second dense fiber mat 14b can define a groove 24. Thus, in aspects where the second dense fiber mat 14b has a greater density than the density of the first fiber mat 14a, the tongue and the groove can be formed in the denser and stronger fiber mat of the second dense fiber mat.

[0073] In a further aspect, the tongue 22 and the groove 24 can extend across the first dense fiber mat 14a and the second dense fiber mat 14b.

[0074] In yet a further aspect, when the surface covering element 10 further includes additional backing materials (e.g., a bottom buffer layer) as further disclosed herein, it is contemplated that the tongue 22 and the groove 24 can extend across one or more of the first dense fiber mat 14a, the second dense fiber mat 14b, and the additional backing material. Alternatively, the tongue 22 and the groove 24 can extend across one or more dense fiber mats and not extend within the additional backing material layer.

[0075] In an exemplary aspect, at least one dense fiber mat 14 can include a first dense fiber mat 14a having a density of 40 lb / ft 3 to about 100 lb / ft 3 of.

[0076] The tongue 22 may have a thickness along the first axis 4. In some aspects, the thickness of the tongue may be less than 2 mm. In a further aspect, the tongue 22 may have a thickness of from about 3 mm to about 0.5 mm or from about 2 mm to about 1 mm. In yet a further aspect, the rigid core 12 may have a thickness along the first axis 4 defined by the spacing between the first surface 16 and the second surface 18, and the tongue 22 may have a thickness along the first axis that is about 10% to about 50% of the thickness of the rigid core. Thus, a thicker rigid core 12 can accommodate a thicker tongue and corresponding groove. However, compared to other surface covering materials, the embodiments disclosed herein can accommodate relatively thin tongues because the fibrous mats 14 (e.g., the second fibrous mat 14b) forming the tongues and grooves have sufficient durability and toughness.

[0077] In some aspects, the first surface 16 of the rigid core 12 may meet the first edge 20a at a first boundary 32 of the rigid core 12. The tongue 22 may project a distance from the first boundary 32 of the rigid core 12 along the second axis 6. In some aspects, the projection distance may be at least 2 mm, or at least 5 mm, or from about 2 mm to about 15 mm. In various aspects, the projection length may be from about 1 / 4 of the thickness of the rigid core 12 to 5 times the thickness of the rigid core. It should be understood that compared to other surface covering materials, the durability and toughness of the embodiments disclosed herein can have tongues with relatively long projection distances. In some aspects and as further described herein, the tongue 22 may have a sufficient projection distance.

[0078] It is contemplated that the fibrous nature of the rigid core 12 can provide a surface profile that has strong frictional engagement with an adjacent rigid core. That is, the interfiber contact between the rigid cores can provide strong frictional engagement. Thus, the fibrous nature of the rigid core can facilitate an interlocking fit of the tongue and groove connection to inhibit relative movement of the joined rigid cores.

[0079] Referring Figure 5 , in some aspects, the tongue 22 may project at an angle relative to the first surface 16. For example, the tongue 22 may have opposing first surface 27 and second surface 28 that are spaced apart along the first axis 4. A reference plane 29 may bisect the opposing first surface 27 and second surface 28 of the tongue. That is, the reference plane may be equidistant from the opposing first surface 27 and second surface 28. The reference plane 29 may form an inclined angle with the first surface 16 of the rigid core 12. The inclined angle may be, for example, from 5 degrees to 45 degrees.

[0080] In a further aspect, the tongue may extend generally parallel to the first surface 16 and the second surface 18. That is, the reference plane 29 may be parallel to the rigid core 12.

[0081] To accommodate the angled tongue, the groove 24 can similarly be angled. For example, the groove 24 can be defined between opposing inner surfaces 34. The opposing inner surfaces 34 can include first opposing portions 38. A second reference plane 36 can bisect the first opposing portions 34. The second plane 36 can form an angled relationship (e.g., the same angle as the tongue) with the first surface 16 of the rigid core 12.

[0082] Optionally, at least one of the opposing inner surfaces 34 defining the groove 24 can include a second portion 44 parallel to the first surface of the rigid core. In this way, the groove 24 can accommodate both angled tongues and non-angled tongues.

[0083] Still referring Figure 13 and 14 , the groove 24 can have a profile that overlaps horizontal tongues (i.e., tongues parallel to the first surface 16 of the rigid core 12) and angled tongues (i.e., tongues not parallel to the first surface). In this way, the groove 34 can be configured to receive a rectangular tongue (shown in dashed lines) or an angled tongue. In this way, the groove can receive either type of tongue. The inner surface 34 of the groove 24 can have a generally parallel portion parallel to the reference plane 29, and the notch 47 forms one of the inner surfaces to receive a portion of the horizontal tongue.

[0084] In some aspects, the rigid core 12 can have a combination of angled tongues and horizontal tongues. For example, the first side 20a and the second side 20b can have angled tongues, and the third side 20c and the fourth side 20d can have horizontal tongues. It is envisioned that the groove 22 can be configured to receive both tongue profiles to allow for connection of the rigid core in different rotational orientations (about the first axis 4).

[0085] Still referring Figure 15 and 16 , it is envisioned that the angled tongue can define a corresponding protruding profile 49 that can be received in the groove 47. In this way, the tongue and groove can have interlocking profiles. It is further envisioned that the groove 24 can be curved to allow for acceptance of the protruding profile 49.

[0086] Although the tongue and groove are shown as having generally rectangular flat ends, it is envisioned that in further aspects, the tongue and / or groove of the rigid core can have rounded or tapered ends. For example, referring Figure 10 , the tongue 22 can have a chamfered edge.

[0087] In some aspects, the tongue 22 and the groove 24 can be formed by machining. When doing so, the machining can impart a surface profile that improves the frictional engagement between the tongue of the adjacent surface covering element and the groove.

[0088] In some aspects, and with reference to Figure 1 , the first edge 20a and the second edge 20b may include opposing ends 50. The plurality of edges further includes opposing third edges 20c and fourth edges 20d that extend between respective opposing ends 50 of the first edge 20a and the second edge 20b. The tongue 22 may be a first tongue 22a, and the groove 24 may be a first groove 24a. The third edge 20c may define a second tongue 22b, and the fourth edge may define a second groove 24b.

[0089] Optionally, the first and second edges may extend perpendicular or substantially perpendicular to the third and fourth edges. In a further aspect, the first and second edges may meet the third and fourth edges at an oblique angle.

[0090] The first edge 20a may have a length along a third axis 8 that is perpendicular to each of the first axis 4 and the second axis 6. In some aspects, the length of the tongue 22 may be equal to or substantially equal to the length of the first edge 20a. In a further aspect, the length of the tongue may be less than the length of the first edge.

[0091] With reference to Figures 7 - 8 , the groove 24 may be defined by opposing legs 48. In some aspects, the rigid core 12 may define at least one through-opening 52 that extends along the first axis through the tongue and at least one through-opening 54 that extends from the first surface 16 of the rigid core 12 to the second surface 18 through the legs 48 that define the groove 24. In this way, adjacent surface covering elements may be arranged such that their respective openings 52, 54 are aligned, and fasteners may be inserted therein to secure their positions relative to one another. In this way, alignment between the surface covering elements may be achieved. For example, in some aspects, the surface covering elements 10 may be arranged in a particular pattern (e.g., a herringbone pattern), and the openings 52, 54 may assist in aligning the particular pattern.

[0092] Optionally, the surface covering element 10 may include a decorative portion 56 having a first surface 58 and an opposing second surface 60, and the second surface 60 of the decorative portion 56 may be attached to the first surface 16 of the rigid core 12.

[0093] In some aspects, one or more (optionally, all) of the dense fiber mats 14 may include randomly oriented fibers. In a further aspect, one or more (optionally, all) of the dense fiber mats 14 may include substantially uniformly oriented fibers.

[0094] In some aspects, one or more (optionally, all) of the dense fiber mats 14 can include a first plurality of fibers 62 and a second plurality of fibers 64. The first plurality of fibers can have a first melting point. At least a portion of the second plurality of fibers can have a second melting point that is lower than the first melting point. In this way, when the first and second pluralities of fibers are heated to a temperature that is higher than the second melting point but less than the first melting point, the second plurality of fibers can bond to the first plurality of fibers. Thus, in some aspects, it is contemplated that the first plurality of fibers 62 (e.g., single fibers) do not melt, while the skin of the second plurality of fibers 64 melts. As described herein, the melting point can refer to the temperature at which a material softens enough to bond to itself and / or other fibers. Thus, the melting point can be a softening point.

[0095] In some aspects, the entirety of the second plurality of fibers can have a second melting point.

[0096] In a further aspect, only a portion of the second plurality of fibers has a second melting point. For example, in some aspects, the second plurality of fibers 64 can include multicomponent fibers. In an exemplary aspect, the multicomponent fibers can be such that only the outer portion 66 of the second plurality of fibers 64 has a second point, and the inner portion of the second plurality of fibers 68 can have a melting point that is higher than the second melting point. In these aspects, the second plurality of fibers 64 can include a skin and a core provided as a skin-core configuration.

[0097] In yet a further aspect, it is contemplated that the first plurality of fibers can have a first melting point; a first portion (e.g., skin) of the second plurality of fibers can have a second melting point, and a second portion (e.g., core) of the second plurality of fibers can have a third melting point. In some aspects, the first and second pluralities of fibers can be heated to a temperature that is higher than the first and second melting points and lower than the third melting point. In this way, the first plurality of fibers and the first portion of the second plurality of fibers can soften and bond together, while the second portion of the second plurality of fibers does not melt. Optionally, in these aspects, the second and third melting points can be the same. For example, the first plurality of fibers and the first portion of the second plurality of fibers can optionally include the same material. Thus, it is contemplated that the skins of both the first plurality of fibers and the second plurality of fibers can melt.

[0098] The surface covering element can be configured for various surfaces. For example, in some aspects, the surface covering element can be a floor element. In a further aspect, the surface covering element can be a wall covering element. In yet a further aspect, the surface covering element can be an erosion control mat.

[0099] Optionally, the rigid core can include light-transmitting fibers.

[0100] The surface covering elements 10 can be configured to be joined to each other to form a surface covering 70. For example, in some aspects, the surface covering elements 10 can include an adhesive 72 on the tongue 22. Optionally, the adhesive can be a compression-activated adhesive. For example, the adhesive can include adhesive elements (e.g., nanospheres) that activate the adhesive when crushed. In these aspects, the surface covering elements can be assembled with corresponding interlocking tongues and grooves, and the assembly can be tapped with a hammer along the interlocking tongues and grooves to activate the adhesive. In further aspects, the adhesive can be an ultraviolet (UV)-activated adhesive. In these aspects, the rigid core 12 of the joined surface covering elements 10 can include light-transmitting fibers to allow activation of the UV-activated adhesive. In some aspects, a release liner 74 can cover the adhesive 72.

[0101] An exemplary surface covering 70 can include a plurality of surface covering elements 10, which include a first surface covering element 10a and a second surface covering element 10b. The tongue 22 of the first surface covering element 10a can be fitted within the groove 24 of the second surface covering element. In some aspects, the adhesive 72 can join the tongue 22 of the first surface covering element 10a to the groove 24 of the second surface covering element 10b.

[0102] In some aspects, the first surface covering element 10a can include at least one through-opening 52 extending through the tongue of the first surface covering element, and the second surface covering element 10b can include at least one through-opening 54 extending through the leg defining the groove. A fastener 76 can extend through each aligned through-opening 52, 54 of the first and second surface covering elements. The fastener can be a staple, nail, screw, tack, earth anchor, soil nail, soil screw, or any other suitable fastener.

[0103] Assembly method of surface covering element

[0104] The tongue 22 of the first surface covering element 10a can be inserted into the groove 24 of the second surface covering element 10b. In some optional aspects, the tongue of the first surface covering element can be bonded to the groove of the second surface covering element. For example, in aspects including a UV-activated adhesive 72, the UV-activated adhesive can be activated with UV radiation.

[0105] Manufacturing method of surface covering element

[0106] The tongue 22 can be formed along a first edge 20a of the rigid core 12. The groove 24 can be formed along a second edge 20b of the rigid core 12. In an exemplary aspect, one or both of the tongue and the groove can be formed by machining. For example, the groove can be machined by a CNC machine. In further aspects, the groove can be machined by a double-end tenoning machine.

[0107] In some aspects, a tongue and groove can be formed without releasing and resetting the rigid core 12. In these aspects, the rigid core can be secured to a machining device (e.g., a CNC machine), and the rigid core can only be released from the machining device after the tongue and groove have been machined. In embodiments including a first tongue 22a and a second tongue 22b and a first groove 24a and a second groove 24b, each of the tongue and the groove can be formed around the perimeter of the rigid core 12 without releasing the rigid core from the machining device. Thus, when forming each edge 20, the rigid core 12 does not need to be reoriented relative to the machining device.

[0108] In some aspects, the rigid core 12 can be formed in a mold. In some optional aspects, each dense fiber mat 14 can be formed in a corresponding mold. In other aspects, multiple dense fiber mats (e.g., a first dense fiber mat 14a and a second dense fiber mat 14b) can be formed in the same mold.

[0109] The fiber mat 80 can be heated at a first temperature for a first period of time. The heated fiber mat can be subjected to pressure by the surface 84 of a press 82. The surface 84 of the press 82 can have a surface temperature lower than the first temperature. Placing the heated fiber mat on the surface of the press can form a dense fiber mat 14.

[0110] In some aspects, the fiber mat 80 can include a first plurality of fibers 62 having a first melting point and a second plurality of fibers 64. At least a portion of the second plurality of fibers 64 can have a second melting point lower than the first melting point. The first temperature of the fiber mat 80 can be greater than the second melting point and lower than the first melting point. For example, in some aspects, such as where the first plurality of fibers includes PET, the first temperature can be about 400°F. This temperature can be lower than the melting point of PET but higher than the second melting point of the second plurality of fibers (or a portion thereof).

[0111] In a further aspect, only a portion of the second plurality of fibers has the second melting point. For example, in some aspects, the second plurality of fibers 64 can include multicomponent fibers. In an exemplary aspect, only the outer portion 66 of the second plurality of fibers 64 has the second point, and the inner portion of the second plurality of fibers 68 can have a melting point higher than the second melting point. In these aspects, the second plurality of fibers can include a skin and a core provided as a core - sheath structure.

[0112] In some aspects, the rigid core 12 can be formed from a plurality of dense fiber mats 14, which at least include a first dense fiber mat 14a and a second dense fiber mat 14b. The plurality of dense fiber mats 14 can be needled to entangle the first dense fiber mat and the second dense fiber mat.

[0113] In some aspects, the first dense fiber mat 14a has a first density, and the second dense fiber mat has a second density greater than the first density. In some optional aspects, the first dense fiber mat 14a can define a first surface 16 of the rigid core 12.

[0114] In some optional aspects, prior to densification, the first and second fiber mats can be needled to entangle the fibers of the first fiber mat with the second fiber mat. For example, one or more needles can be passed through the first fiber mat pad and into the second fiber pad to entangle the fibers of the corresponding dense fiber mats. In this way, once densified, the first dense fiber mat 14a and the second dense fiber mat 14b can remain entangled.

[0115] In a further aspect, the dense fiber mat 14 can further include a third plurality of fibers, which includes natural fibers having a decomposition temperature.

[0116] In a further aspect, a method of manufacturing a surface covering element is described herein, which includes: forming a rigid core, which includes at least one dense fiber mat, and wherein the at least one dense fiber mat includes a first plurality of fibers and a second plurality of fibers.

[0117] In some aspects, the natural fibers can have a decomposition temperature, and the first plurality of fibers or portions thereof (e.g., sheath-core fibers, as further disclosed herein) can have a melting point lower than the decomposition temperature of the first plurality of fibers.

[0118] In some aspects, at least one dense fiber mat can be formed by the following steps: a) superimposing a first plurality of fibers and a second plurality of fibers to form a fiber matrix; b) needling the fiber matrix to form a fiber mat; and c) subjecting the fiber mat to heat and pressure treatment under conditions effective to form the at least one dense fiber mat.

[0119] In some other aspects, a third plurality of fibers can be present. In these aspects, at least one dense fiber mat can be formed by the following steps: a) superimposing a first plurality of fibers, a second plurality of fibers, and a third plurality of fibers to form a fiber matrix; b) needling the fiber matrix to form a fiber mat; and c) subjecting the fiber mat to heat and pressure treatment under conditions effective to form the dense fiber mat.

[0120] It should be further understood that the first, second, and third plurality of fibers can include any of the foregoing fibers.

[0121] It should be further understood that any method of providing fiber entanglement known in the art can be utilized. In some aspects, the needling step is optional. In still other aspects, the needling step can be replaced by hydraulic entanglement, pneumatic entanglement, or any other method capable of holding the fibers together.

[0122] In some aspects, the methods described herein provide a dense fiber mat (e.g., the first fiber mat 14a or the second dense fiber mat 14b) having a respective density of from about 5 lb / ft 3 to about 100 lb / ft 3 , including exemplary densities of 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, and 95 lb / ft 3 . In still further aspects, the bulk density can be a value within any range derived from the above values, including, for example, a density of from about 15 to about 75 pounds per cubic foot.

[0123] In some aspects, the methods described herein provide a dense fiber mat (e.g., the first fiber mat 14a or the second dense fiber mat 14b) having a density of at least about 10 lb / ft 3 , including at least about 15 lb / ft 3 , about 20 lb / ft 3 , about 25 lb / ft 3 , about 30 lb / ft 3 , about 35 lb / ft 3 , about 40 lb / ft 3 , about 45 lb / ft 3 or about 50 lb / ft 3 . In some aspects, the dense fiber mat can have a density within a range between any two of the foregoing values.

[0124] In still other aspects, the methods described herein provide a dense fiber mat (e.g., the first fiber mat 14a or the second dense fiber mat 14b) having a density of no greater than 50 lb / ft 3 , about 45 lb / ft 3 , about 40 lb / ft 3 , about 35 lb / ft 3 , about 30 lb / ft 3 , 25 lb / ft 3 , about 20 lb / ft 3 , about 15 lb / ft 3 or about 10 lb / ft 3 . In some aspects, the dense fiber mat can have a density within a range between any two of the foregoing values. It should be understood that each dense mat can have a density as low as that of a fiber mat comprising substantially the same first plurality of fibers and substantially the same second plurality of fibers that have not been subjected to any densification process, such as heating or pressing.

[0125] In some aspects, the methods described herein provide a combination of dense fiber mats (e.g., a first fiber mat 14a having a first density and a second dense fiber mat 14b having a second density), where the first density can be 10 lb / ft 3 to 30 lb / ft 3 , and the second density is 40 lb / ft 3 and up to about 100 lb / ft 3 . In an exemplary aspect, the first density can be 10 lb / ft 3 to 100 lb / ft 3 , and the second density can be 5 lb / ft 3 to 100 lb / ft 3 , or 30 lb / ft 3 to 100 lb / ft 3 , 75 lb / ft 3 to 120 lb / ft 3 , or about 100 lb / ft 3 . In a further aspect, the first density can be 5 lb / ft 3 to 100 lb / ft 3 , or 5 lb / ft 3 to 30 lb / ft 3 , and the second density can be 40 lb / ft 3 to about 100 lb / ft 3 . In other aspects, the first density can be 5 lb / ft 3 to 100 lb / ft 3 , or 5 lb / ft 3 to 30 lb / ft 3 , and the second density can be 5 lb / ft 3 to 100 lb / ft 3 , or 30 lb / ft 3 to 100 lb / ft 3 , 75 lb / ft 3 to 120 lb / ft 3 , or about 100 lb / ft 3 .

[0126] It should be further understood that the methods described herein provide a dense fiber mat having a density as low as that of a fiber mat, the fiber mat comprising substantially the same first plurality of fibers, substantially the same second plurality of fibers, and substantially the same third plurality of fibers, which fibers have not undergone any densification process, such as heating or addition.

[0127] In some aspects, methods are described herein for providing a rigid core of a surface covering element having a variable density throughout the rigid core. In certain aspects, methods are described herein for providing a rigid core including a first portion having a first density and a second portion having a second density different from the first density. In some aspects, to form a rigid core having different densities, the ratio of first and second pluralities of fibers can be controlled to obtain a desired result. In other aspects, the ratio of first, second, and third pluralities of fibers can be controlled to obtain a desired result.

[0128] It should be understood that the first, second, and third pluralities of fibers can be present in any of the foregoing amounts or ratios.

[0129] In still further aspects, a method for providing a rigid backing portion of a surface covering element having a variable density throughout the rigid core can include forming at least two dense fiber felts. In aspects where two or more dense fiber felts are formed, each of the dense felts can be formed by any of the methods described herein, and the dense felts can exhibit a density that may be the same as or different from another dense fiber felt.

[0130] In certain aspects, the step of superimposing pluralities of fibers can be performed by utilizing a carding and cross-laying system, an air-laying system, or a combination thereof. It should be understood that in some aspects, after the superimposing step, the step of forming the rigid core can further include needling. In still other aspects, the step of forming the rigid core further includes subjecting to heat and pressure treatment under conditions effective to form a dense fiber felt.

[0131] Depending on the temperature at which the surface covering element is heated, the use of a heat-resistant conveyor belt can be desirable. Generally, the surface covering element is heated to a temperature sufficient to at least partially melt the pluralities of fibers having the lowest melting point. In some aspects, the heat treatment conditions effective to form a dense fiber felt can include heating at a temperature of about 180°F to about 800°F, including exemplary temperatures of about 200°F, 250°F, 300°F, 350°F, 400°F, 450°F, 500°F, 550°F, 600°F, 700°F, and about 750°F. In still other aspects, the heat treatment conditions effective to form a dense fiber felt can include heating at a temperature of about 180°F to about 350°F, about 250°F to about 450°F, or about 250°F to about 350°F or about 350°F to about 600°F.

[0132] In some aspects, an oven can be used for heat treatment. In still other aspects, it should be understood that any heating member known in the art can be utilized. For example, in some aspects, the fiber mat can be hot oil calendered. In still further aspects, the heat and pressure can come from a continuous double belt press, such as a press commercially available from TPS-Sandvik, Meyer, Held, Schott and Meissner, or Hymmen. In still other aspects, the heat and pressure can come from single and multiple open die presses.

[0133] During or after the heating step, the fiber mat is optionally subjected to pressure treatment conditions effective to form a dense fiber mat. In these aspects, the fiber mat is subjected to a pressure of from 0 to about 1,200 pounds per square inch (psi), including, for example, from about 10 psi to about 500 psi, 100 to 1,000 psi, from about 250 to 1,000 psi, from about 400 to about 950 psi, from about 500 to 750 psi, or from about 600 to 700 psi.

[0134] Additional details of exemplary rigid cores, methods of making rigid cores, and exemplary apparatuses suitable for making surface covering elements are disclosed in U.S. Patent Application Publication No. 2018 / 0134016A1, the entire disclosure of which is incorporated herein by reference.

[0135] In some aspects, the step of attaching the decorative portion to the first surface of the rigid core can include applying an adhesive. In some aspects, it should be understood that the adhesive material can be applied by any method known in the art. In some aspects, the adhesive can be applied in the form of a hot melt adhesive. In other aspects, the adhesive can be extruded onto the dense fiber mat. In still other aspects, the adhesive material can be applied in the form of an aqueous dispersion.

[0136] In still other aspects, the method further includes applying the substrate layer described above. The substrate layer can be applied by any method known in the art, such as by a roll method or any lamination method known in the art.

[0137] In still other aspects, the decorative portion can be attached to the first surface of the rigid core by any other known method in the art. In some methods, the attaching step includes needling the second surface of the decorative portion to the first surface of the rigid core. In certain aspects, after the decorative portion is adhered to the rigid core, heat pressing can be applied at a temperature of about 230°F (110°C) to about 482°F (250°C) and under sufficient pressure to adhere the decorative portion to the rigid core. In still other aspects, the decorative portion can be attached to the first surface of the rigid core by needling. For example, a decorative portion including multiple brightening PET fibers as a decorative substrate or a decorative surface layer can be attached to the first surface of the rigid core by needling. In other aspects, the decorative portion attached by needling can be further heat pressed to the first surface of the rigid core. It should be understood that the image layer can be transferred to any visible surface of the article by any method known in the art. In some aspects, after the decorative portion is attached to the first surface of the rigid core, the image layer can be formed by direct printing on the substrate. In still other aspects, after the decorative portion is attached to the first surface of the rigid core, the image layer can be transferred by other methods, including but not limited to rotogravure printing, digital and direct pad printing, screen printing, or sublimation.

[0138] In still other aspects, the method further includes the step of applying a wear-resistant layer having a first surface and an opposite surface. In still further aspects, the wear-resistant layer is located above the decorative portion such that the second surface of the wear-resistant layer contacts the first surface of the decorative portion. It should be understood that the wear-resistant layer can be applied by any method known in the art. In some aspects, the wear-resistant layer is applied by a roll method. In these aspects, the wear-resistant layer is applied to the decorative layer and laminated by passing through an additional roll. In other aspects, the wear-resistant layer can be UV-cured.

[0139] For example, the top surface of the decorative layer can optionally be post-pressed, smoothed, embossed, or contoured to obtain various functional or aesthetic effects. Additionally, during the manufacturing process, other optional materials can be applied to the dense fiber mat.

[0140] In combination with any inventive aspect described herein, these methods can optionally include a disinfection step. As will be understood by those skilled in the art, for health and safety purposes, due to the presence of impurities in the recycled carpet material, it may be necessary to disinfect the recycled material. To this end, at any point during manufacturing, a disinfection step can be performed on the multiple fibers: disinfecting the multiple fibers before using them in the methods described herein, or alternatively disinfecting the multiple fibers during or after forming the surface covering element.

[0141] In some aspects, at least one of the dense fiber mats 14 has a weight of about 5 lb / ft 3 to about 100 lb / ft 3densities within the range of, including 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and 95 lb / ft 3 Exemplary densities. In a further aspect, the bulk density can be a value within any range derived from the above values, including, for example, from about 15 to about 75 lb / ft 3 densities.

[0142] In some aspects, at least one of the dense fiber mats 14 has a density of at least about 10 lb / ft 3 densities, including at least about 15 lb / ft 3 , about 20 lb / ft 3 , about 25 lb / ft 3 , about 30 lb / ft 3 , about 35 lb / ft 3 , about 40 lb / ft 3 , about 45 lb / ft 3 or about 50 lb / ft 3 Exemplary values. In some aspects, the dense fiber mat can have a density within a range between any two of the foregoing values.

[0143] In still other aspects, at least one of the dense fiber mats 14 has a density not greater than about 50 lb / ft 3 , about 45 lb / ft 3 , about 40 lb / ft 3 , about 35 lb / ft 3 , about 30 lb / ft 3 , 25 lb / ft 3 , about 20 lb / ft 3 , about 15 lb / ft 3 or about 10 lb / ft 3 densities. In some aspects, the dense fiber mat can have a density within a range between any two of the foregoing values. It should be understood that the dense mats can all have a density as low as that of a fiber mat comprising substantially the same first plurality of fibers and substantially the same second plurality of fibers that have not undergone any densification process, such as a heat treatment or a pressure treatment process.

[0144] In a further aspect, the rigid core can comprise at least two dense fiber mats. In aspects where there are two or more dense fiber mats, each of the dense fiber mats can exhibit a density that may be the same as or different from that of another dense mat. In some aspects, the rigid core can comprise a first dense fiber mat having a third density and a second dense fiber mat having a fourth density. In some aspects, the third density is greater than the fourth density. In still other aspects, the third density is lower than the fourth density. In certain aspects, the first dense fiber mat is adjacent to the first surface of the rigid core, while the second dense fiber mat is adjacent to the second surface of the rigid core. In aspects where there are more than two dense fiber mats, each of the dense fiber mats can be arranged in any configuration determined by one of ordinary skill in the art and used for the end application. In these aspects, each of the dense fiber mats can exhibit the same or different densities.

[0145] In a further aspect, the rigid core of the present invention can exhibit a lower density than a conventional rigid backing portion comprising a layer of polyvinyl chloride material or a wood material as the core, and wherein such a conventional rigid backing does not have a dense fiber mat. In still other aspects, the rigid core of the present invention exhibits a higher porosity than a comparable conventional rigid backing portion comprising a layer of polyvinyl chloride material or a wood material as the core, and wherein such a conventional rigid backing does not have a dense fiber mat.

[0146] In certain aspects, the first and second plurality of fibers can have any variation of a substantially random orientation, a substantially uniform orientation, or a predetermined orientation between random and uniform. Further still, the plurality of fibers themselves can comprise any desired combination of various orientations. In some aspects, the first plurality of fibers is substantially randomly oriented. In still other aspects, the first plurality of fibers is uniformly oriented. In a further aspect, the first plurality of fibers is arranged in a predetermined orientation.

[0147] In some aspects, the second plurality of oriented fibers is substantially randomly oriented. In still other aspects, the second plurality of fibers is uniformly oriented. In a further aspect, the second plurality of fibers is arranged in a predetermined orientation.

[0148] In a further aspect, the first and second plurality of fibers can have the same or different orientations. In some exemplary aspects, the first plurality of fibers can have a substantially random orientation, while the second plurality of fibers can have a uniform orientation. In still other exemplary aspects, the first plurality of fibers can have a uniform orientation, while the second plurality of fibers is substantially randomly oriented. In a further aspect, both the first and second plurality of fibers can have the same orientation.

[0149] In some aspects, the first and second pluralities of fibers can include staple fibers, bulk continuous filaments (BCF), or a combination thereof. In some aspects, the first plurality of fibers can include staple fibers. In other aspects, the first plurality of fibers can include bulk continuous filaments. In still other aspects, the first plurality of fibers can include both staple fibers and bulk continuous filaments.

[0150] In other aspects, the second plurality of fibers can include staple fibers. In other aspects, the second plurality of fibers can include bulk continuous filaments. In still other aspects, the second plurality of fibers can include both staple fibers and bulk continuous filaments.

[0151] In still further aspects, the first plurality of fibers can include staple fibers while the second plurality of fibers can include bulk continuous filaments. In still other aspects, the first plurality of fibers can include bulk continuous filaments while the second plurality of fibers can include staple fibers. In still further aspects, both the first and second pluralities of fibers can include staple fibers. In still other aspects, both the first and second pluralities of fibers can include bulk continuous filaments.

[0152] According to certain aspects, the first and second plurality of fibers can exhibit substantially uniform dimensions, including substantially uniform linear density and substantially uniform fiber length measured in denier units. However, in alternative aspects, the fibers present in the first and second plurality of fibers can have non-uniform linear density and non-uniform fiber length. According to these aspects, the populations of the first and second pluralities of fibers having non-uniform linear fiber density can, for example, have individual linear fiber densities in the range of about 1 to about 500 denier, including exemplary values ​​of about 3 denier, about 5 denier, about 10 denier, about 15 denier, about 20 denier, about 25 denier, about 30 denier, about 35 denier, about 40 denier, about 45 denier, about 50 denier, about 60 denier, about 70 denier, about 80 denier, about 90 denier, about 100 denier, about 120 denier, about 150 denier, about 170 denier, about 200 denier, about 250 denier, about 300 denier, about 350 denier, about 400 denier, and about 450 denier. It should be further understood that the populations of the first and second pluralities of fibers can have individual linear fiber densities in any range between the two aforementioned values. For example, in certain aspects, the individual linear fiber density can be from about 1 to about 5 denier, from about 5 denier to about 25 denier, from about 5 denier to about 200 denier, or from about 100 denier to about 500 denier. Still further, the populations of the first and second plurality of fibers having non-uniform linear density can collectively provide an average linear density, for example, greater than 5 denier, greater than 10 denier, greater than 15 denier, greater than 20 denier, greater than 25 denier, greater than 30 denier, greater than 35 denier, greater than 40 denier, greater than 45 denier, greater than 50 denier, greater than 100 denier, greater than 200 denier, greater than 300 denier, or even greater than 400 denier.

[0153] In other aspects, the first and second pluralities of fibers can each independently include polyester, polypropylene, polyethylene, polyamide, polyurethane, polylactic acid, acetal, copolyester, copolyamide, polystyrene, or combinations thereof.

[0154] Exemplary fibers present in the first and / or second plurality of fibers may include polyamide, polyester, polypropylene, polyethylene, polyurethane, polyethylene terephthalate, polytrimethylene terephthalate, latex, styrene-butadiene rubber, or any combination thereof.

[0155] In some aspects, the dense fibers can further include a third plurality of fibers. In some aspects, the third plurality of fibers can be natural fibers. In yet other aspects, the natural fibers exhibit a decomposition point. In yet other aspects, the third plurality of fibers can include short fibers, loose continuous fibers, or a combination thereof.

[0156] In yet other aspects, the natural fibers include bast, cotton, cellulose, wool, silk, linen, mineral, coconut, glass, or any combination thereof.

[0157] In some aspects, the third plurality of fibers can have a substantially random orientation. In yet other aspects, the third plurality of fibers can have a substantially uniform orientation. In yet further aspects, the third plurality of fibers can have a predetermined orientation.

[0158] In yet further aspects, the third plurality of fibers can exhibit substantially uniform dimensions, including substantially uniform linear density and substantially uniform fiber length measured in denier units. However, in alternative aspects, the fibers present in the third plurality of fibers can have non-uniform linear density and non-uniform fiber length. According to these aspects, the population of the third fibers having a non-uniform linear fiber density can, for example, have an individual linear fiber density in the range of about 1 to about 500 denier, including exemplary values ​​of about 3 denier, about 5 denier, about 10 denier, about 15 denier, about 20 denier, about 25 denier, about 30 denier, about 35 denier, about 40 denier, about 45 denier, about 50 denier, about 60 denier, about 70 denier, about 80 denier, about 90 denier, about 100 denier, about 120 denier, about 150 denier, about 170 denier, about 200 denier, about 250 denier, about 300 denier, about 350 denier, about 400 denier, and about 450 denier. It should be further understood that the populations of the first and second plurality of fibers can have an individual linear fiber density in any range between the two aforementioned values. For example, in certain aspects, the individual linear fiber density can be from about 1 to about 5 denier, from about 5 denier to about 25 denier, from about 5 denier to about 200 denier, or from about 100 denier to about 500 denier. Still further, the populations of the first and second plurality of fibers having non-uniform linear density can collectively provide an average linear density, for example, greater than 5 denier, greater than 10 denier, greater than 15 denier, greater than 20 denier, greater than 25 denier, greater than 30 denier, greater than 35 denier, greater than 40 denier, greater than 45 denier, greater than 50 denier, greater than 100 denier, greater than 200 denier, greater than 300 denier, or even greater than 400 denier.

[0159] In yet other aspects, it should be understood that the decomposition point of the fibers present in the third plurality of fibers is higher than the first and / or second melting points, so that heat treatment effective to cause melting and consolidation of at least one of the first and second plurality of fibers does not cause any substantial decomposition of the natural fibers present.

[0160] In a further aspect, the surface covering element may comprise a) a rigid backing portion including a rigid core having a first surface and an opposite second surface, wherein the rigid core comprises at least one dense fiber mat, and wherein the at least one dense fiber mat is composed of a first plurality of fibers including natural fibers having a decomposition temperature and a second plurality of fibers having a melting point lower than the decomposition temperature of the first plurality of fibers; and b) a decorative portion having a first surface and an opposite second surface, wherein the second surface of the decorative portion is attached to the first surface of the rigid core. It should be understood that in these aspects, the first plurality of fibers including natural fibers may be any of the natural fibers listed above. It should be further understood that the second plurality of fibers may include any of the foregoing fibers or any of the fibers described below.

[0161] In yet other aspects where the first plurality of fibers are not natural fibers, the first plurality of fibers may include multicomponent fibers. In yet other aspects, the second plurality of fibers may include multicomponent fibers. It should be understood that in some aspects of the present invention, multicomponent fibers may be defined as "extruding two polymers from the same spinneret, where both polymers are contained within the filament". In some aspects, the multicomponent fibers may have any cross-sectional shape or geometry that can be envisioned by a person of ordinary skill in the art. In some aspects, the multicomponent fibers may have a cross-sectional structure including, but not limited to, side-by-side type fibers, core-sheath type fibers, sea-island type fibers, and segmented pie cross-sectional types.

[0162] It should be understood that in some aspects, the multicomponent fibers may include at least a first component having a first melting point and at least a second component having a second melting point different from the first melting point. It should be further understood that in some aspects, the at least first component may include a polymer component. In yet other aspects, the at least second component may include a polymer component.

[0163] In still other exemplary aspects, the multicomponent fiber comprises a sheath-core configuration. In some aspects, the sheath comprises a first component. In still other aspects, the core comprises a second component. In still other aspects, the sheath may comprise the second component and the core may comprise the first component. It should be understood that both the sheath and the core may comprise any of the above fibers as components. In some aspects, the polymeric core component may have a higher melting point than the polymeric sheath component. In some aspects, the polymeric core component may comprise polyester, aliphatic polyamide, polyphenylene ether, and / or copolymers or blends thereof. In still other aspects, the polymeric core component may include polyester, polypropylene, polyethylene, polyamide, polyurethane, polylactic acid, acetal, copolyester, copolyamide, polystyrene, or combinations thereof. In still other aspects, the polyester may comprise polyethylene terephthalate, polybutylene terephthalate, or poly(p-phenylene terephthalamide). In still other aspects, the polymeric core comprises polyethylene terephthalate. In a further aspect, the sheath polymer may comprise polyamide, polyethylene, or polyester. In still further aspects, the sheath polymer may include polyester, polypropylene, polyethylene, polyamide, polyurethane, polylactic acid, acetal, copolyester, copolyamide, polystyrene, or combinations thereof. In still further aspects, the sheath polymer may include nylon or polypropylene. In still further aspects, the sheath-core multicomponent fiber comprises polyester as the core component and nylon as the sheath component.

[0164] It should be further understood that in some aspects, the sheath and the core of the multicomponent fiber may comprise the same polymer having different melting points. In still other aspects, the sheath-core multicomponent fiber comprises polyester as the core component and polyethylene as the sheath component. In still other aspects, the sheath-core multicomponent fiber comprises polyester having a first melting point as the core component and polyethylene having a second melting point as the sheath component.

[0165] It should be understood that in aspects where the multicomponent fiber is used in combination with natural fibers, the melting point of each component in the multicomponent fiber is lower than the decomposition temperature of the natural fiber.

[0166] In some aspects, at least one of the dense fiber mats described herein may comprise a first plurality of fibers having a first melting point, wherein the first plurality of fibers comprises single-component fibers. In still other aspects, at least one of the dense fiber mats described herein may comprise a second plurality of fibers comprising a multicomponent fiber that comprises at least a first component having a first melting point and at least a second component having a second melting point.

[0167] In still other aspects, at least one of the dense fiber mats described herein includes a plurality of oriented multi-component fibers, wherein each of the plurality of oriented multi-component fibers includes at least a first component having a first melting point and at least a second component having a second melting point different from the first melting point. In these aspects, the plurality of oriented multi-component fibers can include any of the multi-component fiber configurations described herein. In still other aspects, any of the polymers disclosed herein can be used as any of the components of the plurality of oriented multi-component fibers.

[0168] In still further aspects, the rigid core is substantially free of PVC material, or high-density fiber (HDF) derived from wood material, or medium-density fiber (MDF) derived from wood material. In still further aspects, the rigid core is substantially free of wood material.

[0169] In still other aspects, the rigid core can further include a filler component. Exemplary and non-limiting fillers that can be incorporated into the rigid core can include calcium carbonate, fly ash, recycled calcium carbonate, aluminum trihydrate, talc, nanoclay, barium sulfate, barite, barite glass fiber, glass powder, cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement powder, feldspar, nepheline, magnesia, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanate, glass microspheres, chalk, calcium oxide, and any combination thereof. In some aspects, the filler content can be virgin. In other aspects, the filler content can be recycled. In certain aspects, the filler content can be recycled from post-consumer products. In still other aspects, the filler content can be recycled from post-industrial products.

[0170] In certain aspects, the filler includes one or more of the following: calcium carbonate, aluminum trihydrate, barite, feldspar, cullet, fly ash, kaolin, limestone, polyurethane foam, rubber, thermoplastic powder, thermoplastic polyurethane (TPU), wollastonite, or any combination thereof.

[0171] In still other aspects, the rigid core can further include pigments, flame retardants, surfactants, processing aids, or combinations thereof. In certain aspects, the rigid core can include one or more flame retardant components. Exemplary flame retardants that can be incorporated into the rigid core include, but are not limited to, organophosphorus flame retardants, red phosphorus, magnesium hydroxide, magnesium hydroxide, hexabromocyclododecane, brominated flame retardants, brominated aromatic flame retardants, melamine cyanurate, melamine polyphosphate, melamine borate, pentaerythritol and its derivatives, silica, calcium carbonate, resorcinol bis-(diphenyl phosphate), brominated latex-based, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amines (NOR HAS), triazines and their derivatives, high aspect ratio talc, phosphorylated esters, organically modified nanoclays and nanotubes, non-organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salts, triaryl phosphates, isopropyltriphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkali-activated nanoclays and nanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide, diazene dicarboxamide, azodicarbonamide (ADC), triaryl phosphates, isopropyltriphenyl phosphate, triazine derivatives, alkali-activated organoclays, and alumina. Any desired amount of flame retardant can be used in the rigid core, and the selection of such amounts will depend on the desired application. Such amounts can be readily determined by routine experimentation only.

[0172] In other aspects, any pigments or surfactants known in the art can be utilized. In still other aspects, any processing aids known in the art can be utilized. In some aspects, the processing aids can include, but are not limited to, antistatic chemicals, lubricants, oils, or any combination thereof.

[0173] In still other aspects, at least one of the first, second, or third plurality of fibers can include recycled fibers. In some aspects, the recycled fibers can include post-consumer fibers. In still other aspects, the recycled fibers can include post-industrial fibers. In still other aspects, the recycled fibers can include both post-consumer fibers and post-industrial fibers. It should be understood that the post-consumer fibers and post-industrial fibers can include any of the fibers described above. It should be understood that, in some aspects, the recycled fibers are recycled from carpets or carpet tiles. In still other aspects, the recycled fibers can be fibers recycled from any material, such as any material including polymer fibers and / or natural fibers.

[0174] Recycled fibers can be present in the final rigid core in any desired amount, including, for example, amounts in the range of greater than 0 wt% to 100 wt%, including exemplary amounts of 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% and 95%. In a further aspect, the recycled fibers can be present in amounts within any range derivable from the above values, including, for example, amounts in the range of greater than 0 wt% to 90 wt%, 30 wt% to 70 wt% or 40 wt% to 60 wt%. In other aspects, the surface covering element can comprise at least about 10%, at least about 20%, at least about 30%, at least about 40% or at least about 50% recycled material, such as post-consumer material, post-industrial material, post-commercial material or combinations thereof. In another aspect, the surface covering element comprises from about 50% to about 100% recycled material. It should be further understood that the recycled material in the surface covering element can be present as recycled fibers, recycled fillers or combinations thereof.

[0175] It should be understood that several advantages can be achieved by incorporating recycled material into the surface covering element. For example, second-generation products incorporating recycled material have a smaller environmental footprint relative to traditional composite materials (which include only virgin materials). In a further aspect, the use of recycled material reduces the amount of traditional, typically environmentally harmful materials previously sent to landfills, while still providing the same or similar level of composite material performance. Still further, replacing virgin materials with recycled materials can reduce the manufacturing costs associated with producing various composite products, such as floor covering products. Additionally, incorporating recycled material into the second-generation composite can also provide mechanical reinforcement or stability to the second-generation composite, if desired.

[0176] In certain aspects, it should be understood that the first plurality of fibers, the second plurality of fibers and the third plurality of fibers described herein can be present in any amount to provide a rigid core having a desired density. It should be understood that the first, second and third fibers can be present in any ratio to provide a rigid core having a desired density.

[0177] In some aspects, multiple fibers having the lowest melting point can be present in the final rigid core (or dense fiber mat) in any desired amount, including, for example, amounts in the range of greater than 0 wt% to 100 wt%, including exemplary amounts of 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, and 100%. In still further aspects, multiple fibers having the lowest melting point can be present in an amount within any range derived from the above values, including, for example, from about 0% to about 80% of the total amount of fibers present in the dense fiber mat, alternatively from about 5% to about 60% of the total amount of fibers present in the dense fiber mat, alternatively from about 30% to about 50% of the total amount of fibers present in the dense fiber mat, or still alternatively in an amount in the range of from about 40% to about 60% of the total amount of fibers present in the dense fiber mat. In aspects where at least one multiple fiber comprises a multi-component fiber, the ratio between the respective components having different melting points in the multi-component fiber can be any ratio selected by a person of ordinary skill in the art. In some aspects where both components are present, the weight ratio between the two components having different melting points can be about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, or 1.

[0178] In still other aspects where at least a first multiple fiber comprises a multi-component fiber, at least a first component has a first melting point and at least a second component has a second melting point different from the first melting point, and at least a second multiple fiber comprises multiple single-component fibers having the first melting point, the ratio between the first multiple fiber and the second multiple fiber can be any value determined by a person of ordinary skill in the art to obtain a dense fiber mat having a desired density. In some exemplary aspects, the multi-component fiber can be present in an amount greater than 0 to 100 wt%, including exemplary values of about 1%, about 5%, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, about 99%, and about 99.9%. In some aspects, the multi-component fiber can be present at 100 wt%.

[0179] In certain aspects, the rigid core has a thickness in the range of about 1.5 mm to about 12 mm, including exemplary values of about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, and about 11 mm. In still further aspects, the rigid core can have a thickness within any range between the two aforementioned values. In some aspects, the thickness can be in the range of about 1.5 mm to about 12 mm, about 2 mm to about 12 mm, or about 5 mm to about 12 mm.

[0180] It should be further understood that, in some aspects, the rigid core of the present invention can be water permeable. In still other aspects, the rigid core of the present invention is water impermeable. In yet further aspects, the rigid core of the present invention does not accumulate or retain water in the dense fiber mat. It should be further understood that water does not change the rigid core. In certain aspects, water does not change the mechanical properties of the rigid core.

[0181] In certain aspects, the surface covering element described herein can exhibit a Class I radiant panel test rating according to ASTM E-648 standard.

[0182] In still other aspects, when measured according to ASTM F-1914-07(2011), the surface covering element exhibits a residential indentation of less than 0.0005 inches. In still other aspects, when measured according to ASTM F-1914-07(2011), the surface covering element exhibits a commercial dent of less than 0.0005 inches.

[0183] In still other aspects, the surface covering element passes the bend radius test measured according to ASTM F137(2013). In certain aspects, when a sample of the article of the present invention is bent around a 1” mandrel, if no cracks or fractures are observed, the test is considered passed. In other aspects, when a sample of the article of the present invention is bent around a >0.25” mandrel, if no cracks or fractures are observed, the test is considered passed.

[0184] It should be understood that the stiffness of the product can be determined by measuring the flexural modulus and the flexural strength of the article.

[0185] In some aspects, the flexural modulus and flexural strength can be measured by a three-point bending flexure test. In some aspects, the flexural modulus (also known as the bending modulus) is calculated as the ratio of stress to strain in flexural deformation, or the tendency of the material to bend. In certain aspects, this value measured in force / area units is determined by the slope of the stress-strain curve generated by a flexure test (e.g., a test according to ASTM D790 standard). A rectangular beam that behaves as an isotropic linear material is used for the test, and this rectangular beam has a width w and a height h. In addition to the width w and height h of the beam, the values used in the test also include the distance L measured between two external supports, the second moment of inertia I (not shown) of the cross-sectional area of the beam, and the deflection d due to the load F applied at the middle of the beam. The calculation of the flexural modulus can be completed according to formula (1)

[0186]

[0187] According to the elastic beam theory, d can be obtained according to formula (2)

[0188]

[0189] Again, where I is the moment of inertia of the cross-section and E is the modulus of elasticity. For a rectangular beam, I is determined according to Equation (3).

[0190]

[0191] Thus, E f = E, that is, E f is equal to Young's modulus or the modulus of elasticity.

[0192] Unconstrained by theory, ideally, the flexural or bending modulus of elasticity is equivalent to the tensile modulus (Young's modulus) or the combined modulus of elasticity. However, as will be readily understood by one of ordinary skill in the art, polymers are part of an unpredictable realm, and thus, the value of the flexural modulus can vary widely.

[0193] Building codes determine the maximum deflection, which is typically a fraction of the span, such as 1 / 400 or 1 / 600. Thus, the allowable stress (or strength limit state) or the serviceability limit state (various deflection considerations) may affect the minimum size of the members required for testing.

[0194] In some aspects, the surface covering element exhibits a flexural modulus of from about 0.1 to about 15.0 GPa, including exemplary values of about 0.5 GPa, about 1 GPa, about 1.5 GPa, about 2 GPa, about 2.5 GPa, about 3 GPa, about 3.5 GPa, about 4 GPa, about 4.5 GPa, about 5 GPa, about 5.5 GPa, about 6 GPa, about 6.5 GPa, about 7 GPa, about 7.5 GPa, about 8 GPa, about 8.5 GPa, about 9 GPa, about 9.5 GPa, about 10 GPa, about 10.5 GPa, about 11 GPa, about 11.5 GPa, about 12 GPa, about 12.5 GPa, about 13 GPa, about 13.5 GPa, about 14 GPa, and about 14.5 GPa.

[0195] In still other aspects, the surface covering element exhibits a flexural strength of from about 20 to about 400 MPa, including exemplary values of about 30 MPa, about 50 MPa, about 70 MPa, about 100 MPa, about 130 MPa, about 150 MPa, about 170 MPa, about 200 MPa, about 230 MPa, about 250 MPa, about 270 MPa, about 300 MPa, about 330 MPa, about 350 MPa, and about 370 MPa.

[0196] In a further aspect, the surface covering element exhibits substantially balanced component stress. In certain aspects of the present invention, the surface covering element exhibits substantially uniform stability across the article and thus does not require an adaptation period to allow the stress to equalize prior to any installation. In still other aspects, the dimensional stability and the lack of need for an adaptation period can be measured according to the ISO 23999 hot curl dimensional stability standard. In certain aspects, when the article is heated to about 80 °C / 180 °F and then cooled back to ambient temperature, the dimensional stability can be measured by analyzing the dimensional change of the article. The maximum change shown in such a manner can be no more than about 0.05%, no more than about 0.1%, no more than about 0.11%, no more than about 0.12%, no more than about 0.13%, no more than about 0.14%, no more than about 0.15%, no more than about 0.16%, no more than about 0.17%, no more than about 0.18%, no more than about 0.19%, no more than about 0.20%, no more than about 0.25%, no more than about 0.30%, no more than about 0.35%, no more than about 0.40% or no more than about 0.5%. In still other aspects, the maximum change observed can be within any range of values derived from any two of the foregoing values. In some aspects, the maximum change is from about 0.1% to about 0.2% or from about 0.15% to about 0.5%. In still other aspects, when the article is heated to 80 °C / 180 °F and then cooled to ambient temperature, the maximum change is no greater than 0.17%.

[0197] In certain aspects, the decorative portion of the article of the present invention includes a decorative substrate layer or a decorative surface layer. As used herein, it should be understood that the terms decorative substrate layer and decorative surface layer can be used interchangeably. In some aspects, the decorative surface layer includes polyvinyl chloride (PVC), whitened PVC, opaque PVC, oriented polypropylene (OPP), polyolefin (PO), woven polyethylene (PE), non-woven PE, woven polypropylene (PP), non-woven PP, woven PET, whitened fiber PET, non-woven PET, woven nylon, non-woven nylon, conventional paper, conventional foil or oriented polypropylene with a foil applied. In still further aspects, the decorative surface layer can include one or more of the following: heat-stabilized biaxially oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), modified polyethylene terephthalate (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA), copolymer, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPS), polycarbonate, polyethylene (PE) or its copolymer.

[0198] In some aspects, the surface layer has a thickness of from about 1 mil to about 20 mils, including exemplary values of about 2 mils, about 3 mils, about 4 mils, about 5 mils, about 6 mils, about 7 mils, about 8 mils, about 9 mils, about 10 mils, about 11 mils, about 12 mils, about 13 mils, about 14 mils, about 15 mils, about 16 mils, about 17 mils, about 18 mils, and about 19 mils. In a further aspect, the substrate layer can have any thickness within a range derived from any two of the exemplary values listed above. For example, the substrate layer can have a thickness within the range of about 1 mil to about 5 mils, or about 3 mils to about 7 mils, or about 7 mils to about 20 mils. In a further aspect, the substrate layer can be a film.

[0199] In still other aspects, the decorative portion includes an image layer. In some aspects, the image layer is printed or otherwise transferred onto the surface of the decorative substrate layer or the decorative surface layer. In still other aspects, the image layer is printed or otherwise transferred onto the surface of any visible layer. In some aspects, the substrate layer and the visible layer are the same. In other aspects, the substrate layer and the visible layer are different.

[0200] In some aspects, the decorative layer is attached to the first surface of the rigid core with an adhesive. It should be understood that the adhesive can be any adhesive known in the art. In some aspects, the adhesive includes at least one of an acrylic adhesive, ethylene-vinyl acetate (EVA), ethylene-acrylic acid (EAA), ethylene-acrylic acid-maleic anhydride (EAA-MAH), ethylene-methyl acrylate-maleic anhydride (EMA-MAH), ethylene-vinyl acetate-maleic anhydride (EVA-MAH), low density polyethylene-maleic anhydride (LDPE-MAH), high density polyethylene-maleic anhydride (HDPE-MAH), polyurethane (PUR), polyurethane dispersion (PUD), UV curable adhesive, or a combination thereof. In some aspects, the polyurethane dispersion can include isocyanate-terminated urethane polymers, methylene bis(phenyl isocyanate), methylene diphenyl diisocyanate, etc. The polyurethane dispersion can further include oxazolidine hardeners and various modifiers.

[0201] In some aspects, the UV curable adhesive can include a polyurethane acrylate-based backbone polymer, a polyisoprene acrylate-based backbone polymer, a polybutadiene acrylate-based backbone polymer, monomer (meth)acrylate, etc. In certain aspects, the UV curable adhesive can include any adhesive known in the art that is capable of curing upon exposure to ultraviolet light. In other aspects, the UV curable adhesive can further include other additives, such as, for example but not limited to, photoinitiators, additives that increase the flexibility of the resin, etc.

[0202] In a further aspect, the adhesive comprises ethylene-vinyl acetate (EVA). In yet other aspects, the adhesive comprises ethylene-acrylic acid (EAA). In a further aspect, the adhesive comprises polyurethane dispersion (PUD), polyurethane reactive (PUR) hot melt adhesive.

[0203] The adhesive may comprise substantially linear ethylene polymers and uniformly branched linear ethylene polymers (i.e., uniformly branched ethylene polymers). Relative to conventional ethylene polymers such as low density polyethylene (LDPE), non-uniformly branched linear low density polyethylene (LLDPE), high density polyethylene (HDPE), and non-uniformly branched ultra low density polyethylene (ULDPE), uniformly branched ethylene polymers (especially including substantially linear ethylene polymers) have a low curing temperature, good adhesion to polypropylene, and low modulus.

[0204] In some aspects, the adhesive has a thickness of from about 0.1 mil to about 5 mils, including exemplary values of about 0.5 mil, about 1 mil, about 1.5 mils, about 2 mils, about 2.5 mils, about 3 mils, about 3.5 mils, about 4 mils, and about 4.5 mils. In a further aspect, the adhesive may have any thickness within a range derived from any two of the exemplary values listed above. For example, the adhesive may comprise a thickness within the range of about 0.5 mil to about 4 mils, or about 0.1 mil to about 3 mils.

[0205] In still other aspects, the decorative portion can be attached to the first surface of the rigid core by any other known method in the art. In some exemplary aspects, the decorative portion can be attached to the first surface of the rigid core by needling. For example, a decorative portion including a variety of brightening PET fibers as a substrate can be attached to the first surface of the rigid core by needling. In other aspects, the decorative portion attached by needling can be further heat-pressed to the first surface of the rigid core. In these aspects, after the decorative portion is attached to the first surface of the rigid core, an image layer can be formed by direct printing on the substrate. In such aspects, random fibers having a white or near-white base tone can be attached to the first surface of the rigid core. The fibers used to form the substrate can include at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90% or at least about 95% of low-melting-point fibers, which can form a bond with the rigid core when heated to a temperature of about 110 to about 250 °C, including exemplary values of about 120 °C, about 130 °C, about 140 °C, about 150 °C, about 160 °C, about 170 °C, about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C and about 240 °C. In still other aspects, the resulting surface can be further flattened by a belt or using a release film or paper to maintain a certain level of smoothness, thereby allowing the transferred image to have sufficient detail.

[0206] In some aspects, the image layer can include any conventional ink, dye, pigment or other marking substance that can be applied in a desired pattern. By way of example and not limitation, the image layer can include water-based, soy-based UV-curable inks and / or solvent-based pigments. In still further aspects, the image layer is a UV-curable ink.

[0207] It should be understood that UV-curable inks can include photoinitiators, pigments, additives, monomers and oligomers of various polymers, etc. In some exemplary aspects, UV-curable inks can include, but are not limited to, (5-ethyl-1,3-dioxolan-5-yl)methyl acrylate, 2-phenoxyethyl acrylate; 1-vinylhexahydro-2H-azepin-2-one, substituted phosphine oxides, trimethylolpropane triacrylate, phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide, epoxy acrylate oligomers, diacrylate monomers, polyfunctional monomers, amine-modified acrylate oligomers, 1-vinylhexahydro-2H-azepin-2-one, diacrylate oligomers, benzophenone, triacrylate monomers, 1-hydroxy-cyclohexyl phenyl-ketone, 2-hydroxy-2-methylpropiophenone, etc.

[0208] It should be further understood that the image layer can be applied to the decorative substrate layer or the decorative surface layer or any other visible layer by any conventional printing method, which may include but is not limited to direct printing, rotogravure printing, digital printing, screen printing, flexographic printing, lithographic printing, offset lithographic printing, letterpress printing, hot melt printing, heat sublimation printing, dye sublimation printing, heat transfer printing, digital printing, etc. In still other aspects, the image layer can be applied by reverse printing. In such exemplary aspects, the image is printed on the underside of the transparent film rather than on the top side of the film.

[0209] In still further aspects, the image layer can be applied by digital printing. In some aspects, the image layer is applied before attaching the decorative part to the rigid core. In other aspects, the image layer is applied after attaching the decorative part to the rigid core. In exemplary aspects, the image layer can include inks and pigments manufactured by INX Inks, Durst, HP, EFI, Sun Chemical, DyStar, Sensient Inks Technologies, Kao Collins, Mankiewicz, Marabu, Borbeaux, or Tiger. In still other aspects, the image layer can be digitally printed using a digital printing press manufactured by Cefla, Durst, Hymmen, EFI, Barbaran, Zimmer Austria, HP, Fujifilm, Mimaki, AGFA, Kodak, Canon, Epson, KBA, OKI, Ricoh, Heidelberg, Mutoh, or Inca.

[0210] In certain aspects, the formed image layer can be a continuous layer that substantially covers the entire top surface of the substrate. In still other aspects, the formed image layer can be a discontinuous layer that only covers a part of the top surface of the substrate. In still other aspects, the image layer can have any desired aesthetic appearance. In some exemplary aspects, the image layer can have the appearance of imitation hardwood or ceramic flooring.

[0211] In some aspects, the decorative layer portion can have any suitable weight and thickness. In some embodiments, the weight of the decorative layer portion is from about 0.2 ounces per square yard to about 1.0 ounce per square yard, including but not limited to the weight of the decorative layer portion being about 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, and 0.9 ounces per square yard. In further aspects, the decorative layer portion can have a total thickness from about 1 mil to about 20 mils, including exemplary values of about 2 mils, about 3 mils, about 4 mils, about 5 mils, about 6 mils, about 7 mils, about 8 mils, about 9 mils, about 10 mils, about 11 mils, about 12 mils, about 13 mils, about 14 mils, about 15 mils, about 16 mils, about 17 mils, about 18 mils, and about 19 mils; even though in fact any thickness can be used.

[0212] In still other aspects, the decorative layer can further include an aesthetic layer, such as a thin veneer of slate, ceramic, stone, wood, cork, film, woven or non-woven material.

[0213] In still other aspects, the decorative layer can include woven fibers, stone, ceramic, glass, needlepunched cotton, leather, animal fur, veneer, or any combination thereof.

[0214] In additional aspects, any of the aesthetic layers described above can be adhered to any of the aforementioned substrates.

[0215] In still other aspects, the decorative portion further includes a wear-resistant layer adhered to the image layer. In still other aspects, the wear-resistant layer is absent. In aspects where the wear-resistant layer is present, the wear-resistant layer can include, for example but not limited to, conventional ionomers, polyethylene terephthalate (PET), polyurethane, polypropylene, polytrimethylene terephthalate (PTT), polyamide, polyvinyl chloride (PVC), etc. In additional aspects, the wear-resistant layer can include a surlyn resin, such as for example but not limited to that manufactured by E.I. duPont de Nemours and Company, Inc 1706 resin.

[0216] In still additional aspects, the wear-resistant layer can include heat-stabilized biaxially oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), modified polyethylene terephthalate (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA), copolymer, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), polycarbonate, polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), or a copolymer thereof.

[0217] In some aspects, the wear layer is substantially transparent. In other aspects, the wear layer is substantially opaque.

[0218] In still further aspects, the wear layer has a thickness in the range of greater than 0 mils to 30 mils, including exemplary thickness ranges of about 0.5 mil, about 1 mil, about 1.5 mil, about 2 mil, about 2.5 mil, about 3 mil, about 3.5 mil, about 4 mil, about 5 mil, about 6 mil, about 7 mil, about 8 mil, about 9 mil, about 10 mil, about 12 mil, about 15 mil, about 17 mil, about 20 mil, about 22 mil, about 25 mil, and about 27 mil. In yet further aspects, the thickness of the wear layer can be in a range derived from any of the exemplary values listed above. For example, the thickness can be in a range of up to 4 mils or in a range of about 4 mils to about 9 mils or about 4 mils to about 16 mils.

[0219] In some aspects, the wear layer is laminated to the decorative portion. In still other aspects, the wear layer is UV cured to the decorative portion. In some aspects, in the absence of the wear layer, a spray material can be applied to the top surface of the decorative portion. In such aspects, the sprayed material can be used as a primer.

[0220] In certain aspects, the decorative portion has a top layer. In yet other aspects, the top surface of the decorative portion is embossed or line embossed. It should be understood that in aspects where the wear layer is present, the top layer of the decorative portion is the wear layer. In aspects where the wear layer is absent but the decorative portion includes a substrate layer, the substrate surface is the top layer of the decorative portion. In aspects where any additional aesthetic layer is present and the wear layer is absent, the surface aesthetic layer is the top surface of the decorative portion. In certain aspects, the wear layer is a scratch layer. In aspects where the wear layer is absent, the scratch layer can be directly applied to the top surface of the decorative layer. It should be understood that the scratch layer can be applied by any method known in the art. In some aspects, the scratch layer can include any material suitable for this purpose. In still further aspects, the scratch layer can include a polyurethane-based transparent material or an acrylic-based transparent material. In still further aspects, the scratch layer can be UV cured.

[0221] Embossing can be performed to provide graphic portions and textures, thereby replicating wood grain, slate, and other graphic portions. Laser etching can also be used instead of embossing to achieve the desired aesthetics. Some other potential methods for texturing the surface of floor materials, wall panels, ceiling, or roof products include dragging wiring while the temperature of the extruded product is still above the glass transition temperature, or dragging a probe across the surface while the product or the probe is moving. Additionally, the texture can also be embedded in the surface of an injection mold, a compression mold, or a vacuum forming mold. The texture can also be hot or cold stamped under pressure to produce the desired style. It should be understood that embossing can be performed by any technique known in the art. In some aspects, an embossing roll, film, or UV "freeze" embossing can be used. In still other aspects, embossing can be performed by using heat or inert UV curing under a film or strip. In some exemplary aspects, embossing can be performed by applying a viscous liquid that can cure and crosslink. In some other aspects, a textured film can be applied to the viscous liquid, which then cures through the film to form a textured surface that reflects the texture present on the textured film.

[0222] In certain aspects, the embossing can be pressed into or cured within a scratch layer or a wear layer. In other aspects, an image layer including the embossing can be pressed into or cured into the scratch layer or the wear layer by various means (such as but not limited to by UV curing molding methods).

[0223] Surface covering elements can generally have any desired shape. In one aspect, the surface covering element is substantially planar. The planar composite article can be used for floor coverings or surfacing materials, wall panels, etc. The planar composite article can be manufactured in any desired size, which generally depends on the target application. In one aspect, the length dimension of the planar composite article can be greater than the width dimension. For example, the size of the planar composite article can be adjusted as a sheet, such as a 4'×8' sheet. Such a sheet can be cut into smaller sizes as needed. In other aspects, the size of the composite article can be adjusted to a 4'×8' composite or a 4'×10' composite or other elongated sizes such as 5'×12', etc. In other aspects, the size of the composite article can be further adjusted to fit the final product. The elongated composite article can be used as, for example, a surfacing material. The composite article can also have any desired thickness. In one aspect, the composite material has a thickness of about 0.25 to about 3 inches, or 0.5 inches to 1.0 inches, or about 0.25 to about 0.75 inches, or about 0.6 to about 0.75 inches. In a further aspect, the composite article can have suitable shapes and sizes commonly used for floor tiles, wall tiles, ceiling tiles, including but not limited to sizes such as 1'×1', 2'×2', 3'×3, 3'×5', etc. In some aspects, the flooring article can be configured as a panel, plank, sheet, board, or tile. In other aspects, the surface covering element is a wall panel article. In still other aspects, the surface covering element is a ceiling article. Other shapes include diamond, rectangle, triangle, circle, and other shapes.

[0224] In some aspects, the surface covering element includes a plurality of side edges. In certain aspects, the profile of the plurality of side edges is not designed to define any form of interlocking or other fastening mechanism by which adjacent articles can be attached to each other. In a further aspect, the profile of the plurality of side edges is designed to form an interlocking mechanism. It should be understood that any known interlocking mechanism in the art can be formed.

[0225] In a further aspect, the surface covering element can be directly adhered to the underlying surface. In a still further aspect, the surface covering element can be laid loosely on the underlying surface. In still other aspects, the surface covering element can be adhered to the surface with locking points, adhesive strips, etc. In a still further aspect, the surface covering element can be attached to the underlying surface in a magnetic manner. In some exemplary aspects, the underlying surface can be coated, for example, with any substance having magnetic properties or containing a material that is otherwise attracted by a magnetic material. For example, the underlying floor can be coated with iron oxide or iron. In such aspects, the surface covering element can further include any substance that exhibits magnetic properties, and once the floor is installed, the surface covering element can be connected to the underlying floor where a magnetic field exists.

[0226] In a further aspect, the surface covering element can be attached to an additional backing material. It should be understood that the attachment of the surface covering element to other backing materials can be accomplished by any method known in the art. For example, and without limitation, the attachment can be accomplished by applying an adhesive material or freely laying the surface covering element on an additional backing. In yet other exemplary aspects, the additional backing material can be a backing film, foam, glue or adhesive layer, or other padded or cushioned backing (such as cork). In certain aspects, the additional backing can include an anti-slip backing, pad, embossed back, foam, carpet backing or any combination thereof.

[0227] It should be understood that the anti-slip backing, pad, embossed backing, foam or carpet backing can include any material known in the art. In some aspects, they can include polyurethane foam. In other aspects, they can include plastic polyethylene-based foam or backing, such as HBEP or SLEP-based foam. Descriptions of exemplary backings can be found, for example, in U.S. Patent Application No. 11 / 915,553, U.S. Patent Application No. 12 / 786,036, U.S. Patent Application No. 12 / 619,059 or U.S. Patent No. 9,410,026, which are incorporated herein by reference in their entirety.

[0228] In various aspects, the surface covering elements disclosed herein advantageously exhibit a higher radiant panel rating, short and sharp sound reduction, improved noise reduction characteristics and less embodied energy.

[0229] Exemplary aspects

[0230] In view of the described products, systems and methods and their variations, certain more specifically described aspects of the present invention are described hereinafter. However, these specifically described aspects should not be construed as having any limiting effect on any different claims containing the different or more general teachings described herein, or that the "specific" aspects are in some way limited to a meaning different from the inherent meaning of the language literally used therein.

[0231] Aspect 1: A surface covering element, comprising:

[0232] A rigid core, comprising at least one dense fiber mat, the rigid core comprising a first surface and an opposite second surface spaced apart along a first axis, wherein the rigid core comprises a plurality of edges defining an outer periphery of the rigid core,

[0233] Wherein the plurality of edges at least include a first edge and an opposite second edge spaced apart along a second axis perpendicular to the first axis, wherein the first edge includes a tongue, and wherein the second edge defines a groove.

[0234] Aspect 2: The surface covering element according to Aspect 1, wherein the at least one compact fiber mat is a plurality of layers of compact fiber mats.

[0235] Aspect 3: The surface covering element according to Aspect 2, wherein the plurality of layers of compact fiber mats at least includes a first compact fiber mat and a second compact fiber mat, wherein the first compact fiber mat has a first density, and wherein the second compact fiber mat has a second density greater than the first density.

[0236] Aspect 4: The surface covering element according to Aspect 3, wherein the first and second compact fiber mats are needled together.

[0237] Aspect 5: The surface covering element according to Aspect 3 or Aspect 4, wherein the first compact fiber mat defines the first surface.

[0238] Aspect 6: The surface covering element according to any one of Aspects 3 to 5, wherein the second density is 40 lb / ft 3 to about 100 lb / ft 3 .

[0239] Aspect 7: The surface covering element according to any one of Aspects 3 to 6, wherein the first density is 10 lb / ft 3 to 30 lb / ft 3 .

[0240] Aspect 8: The surface covering element according to any one of Aspects 3 to 7, wherein the second compact fiber mat defines the tongue, and wherein a portion of the second compact fiber mat defines the groove.

[0241] Aspect 9: The surface covering element according to any one of the foregoing aspects, wherein the at least one compact fiber mat includes a first compact fiber mat having a density of 40 lb / ft 3 to about 100 lb / ft 3 .

[0242] Aspect 10: The surface covering element according to any one of the foregoing aspects, wherein the tongue has a thickness along the first axis, and wherein the thickness of the tongue is about 0.5 mm to about 3 mm.

[0243] Aspect 11: The surface covering element according to Aspect 8, wherein the thickness of the tongue is about 1 mm.

[0244] Aspect 12: The surface covering element according to aspect 8 or aspect 9, wherein the first surface of the rigid core meets the first edge at a first boundary of the rigid core, wherein the tongue projects a distance along the second axis from the first boundary of the rigid core, and wherein the projected distance is at least 2 mm.

[0245] Aspect 13: The surface covering element according to any one of the preceding aspects, wherein the tongue has opposite first and second surfaces spaced apart along the first axis, wherein a reference plane bisects the opposite first and second surfaces of the tongue, and wherein the reference plane forms an inclined angle with the first surface of the rigid core.

[0246] Aspect 14: The surface covering element according to any one of aspects 1 to 10, wherein the tongue has opposite first and second surfaces spaced apart along the first axis, wherein a reference plane bisects the upper and lower surfaces of the tongue, and wherein the reference plane is parallel to the first surface of the rigid core.

[0247] Aspect 15: The surface covering element according to aspect 13, wherein the groove is defined between opposite inner surfaces, wherein the opposite inner surfaces include a first opposite portion, wherein a second reference plane bisects the first opposite portion, and wherein the second plane forms an inclined angle with the first surface of the rigid core.

[0248] Aspect 16: The surface covering element according to aspect 13, wherein at least one of the opposite inner surfaces defining the groove includes a second portion parallel to the first surface of the rigid core.

[0249] Aspect 17: The surface covering element according to any one of the preceding aspects, wherein the tongue and the groove are formed by machining.

[0250] Aspect 18: The surface covering element according to any one of the preceding aspects, wherein the first and second edges include opposite ends, wherein the plurality of edges further includes opposite third and fourth edges extending between the respective opposite ends of the first and second edges, wherein the tongue is a first tongue, wherein the groove is a first groove, wherein the third edge defines a second tongue, and wherein the fourth edge defines a second groove.

[0251] Aspect 19: The surface covering element according to aspect 16, wherein the first and second edges extend perpendicular or substantially perpendicular to the third and fourth edges.

[0252] Aspect 20: The surface covering element according to any one of the preceding aspects, wherein the first edge has a length along a third axis perpendicular to each of the first and second axes, and wherein the length of the tongue is equal to or substantially equal to the length of the first edge.

[0253] Aspect 21: The surface covering element according to any one of aspects 1 to 17, wherein the first edge has a length along a third axis perpendicular to each of the first and second axes, and wherein the length of the tongue is less than the length of the first edge.

[0254] Aspect 22: The surface covering element according to any one of the preceding aspects, wherein the groove is defined by opposing legs, and wherein the rigid core defines:

[0255] At least one through-opening extending along the first axis through the tongue; and

[0256] At least one through-opening extending from the first surface of the rigid core to the second surface through the legs defining the groove.

[0257] Aspect 23: The surface covering element according to any one of the preceding aspects, further comprising a decorative portion having a first surface and an opposing second surface, wherein the second surface of the decorative portion is attached to the first surface of the rigid core.

[0258] Aspect 24: The surface covering element according to any one of the preceding aspects, wherein the at least one dense fiber mat comprises randomly oriented fibers.

[0259] Aspect 25: The surface covering element according to any one of the preceding aspects, wherein the at least one dense fiber mat comprises substantially uniformly oriented fibers.

[0260] Aspect 26: The surface covering element according to any one of the preceding aspects, wherein the at least one dense fiber mat comprises a first dense fiber mat, the first dense fiber mat comprising a first plurality of fibers having a first melting point and a second plurality of fibers, wherein at least a portion of the second plurality of fibers has a second melting point lower than the first melting point.

[0261] Aspect 27: The surface covering element according to aspect 26, wherein the at least a portion of the second plurality of fibers having the second melting point is an outer portion of the fibers of the second plurality of fibers.

[0262] Aspect 28: The surface covering element according to any one of the preceding aspects, wherein the at least one dense fiber mat comprises a first dense fiber mat, the first dense fiber mat comprising a first plurality of fibers having a first melting point and a second plurality of fibers, wherein the second plurality of fibers comprises multicomponent fibers, wherein the multicomponent fibers comprise a skin and a core provided as a skin-core configuration, and wherein the skin has a second melting point lower than the first melting point.

[0263] Aspect 29: The surface covering element according to any one of the preceding aspects, wherein the surface covering element is a floor element.

[0264] Aspect 30: The surface covering element according to any one of Aspects 1 to 25, wherein the surface covering element is a wall covering element.

[0265] Aspect 31: The surface covering element according to any one of Aspects 1 to 25, wherein the surface covering element is an erosion control mat.

[0266] Aspect 32: The surface covering element according to any one of the preceding aspects, wherein the rigid core comprises light-transmitting fibers.

[0267] Aspect 33: The surface covering element according to any one of the preceding aspects, further comprising an adhesive on the tongue.

[0268] Aspect 34: The surface covering element according to Aspect 30, further comprising a release liner covering the adhesive.

[0269] Aspect 35: A surface covering, comprising:

[0270] A plurality of surface covering elements according to any one of the preceding aspects, wherein the plurality of surface covering elements comprises a first surface covering element and a second surface covering element, wherein the tongue of the first surface covering element fits into the groove of the second surface covering element.

[0271] Aspect 36: The surface covering according to Aspect 32, further comprising an adhesive that couples the tongue of the first surface covering element to the groove of the second surface covering element.

[0272] Aspect 37: The surface covering according to Aspect 32, wherein the adhesive comprises a compression-activated adhesive.

[0273] Aspect 38: The surface covering according to Aspect 32, wherein the adhesive comprises an ultraviolet-activated adhesive.

[0274] Aspect 39: The surface covering according to any one of aspects 32 to 35, wherein the first surface covering element defines at least one through-opening extending along the first axis through the tongue.

[0275] wherein the groove of the second surface covering element is defined by a pair of legs, and wherein the second surface covering element defines at least one through-opening extending from the first surface to the second surface of the rigid core through the legs defining the groove.

[0276] wherein the surface covering further comprises at least one fastener, each of the at least one fasteners extending through each of the following:

[0277] one of the at least one through-openings extending through the tongue of the first surface covering element; and

[0278] one of the at least one through-openings extending through the legs defining the groove.

[0279] Aspect 40: A method of assembling a surface covering, the surface covering comprising a plurality of surface covering elements according to any one of aspects 1 to 34, the plurality of surface covering elements including at least a first surface covering element and a second surface covering element, the method comprising:

[0280] inserting the tongue of the first surface covering element into the groove of the second surface covering element.

[0281] Aspect 41: The method according to aspect 40, further comprising bonding the tongue of the first surface covering element to the groove of the second surface covering element.

[0282] Aspect 42: The method according to aspect 41, wherein bonding the tongue of the first surface covering element to the groove of the second surface covering element comprises activating a UV-activated adhesive with UV radiation.

[0283] Aspect 43: A method, comprising:

[0284] forming a tongue along a first edge of a rigid core, the rigid core comprising at least one dense fiber mat, the dense fiber mat comprising a first surface and an opposite second surface spaced apart along a first axis, wherein the rigid core comprises a plurality of edges defining an outer perimeter of the rigid core, the plurality of edges including at least the first edge and an opposite second edge spaced apart along a second axis perpendicular to the first axis.

[0285] Aspect 44: The method according to aspect 43, further comprising:

[0286] Form a groove along the second edge.

[0287] Aspect 45: The method according to aspect 43 or aspect 44, wherein forming the tongue along the first edge includes machining the tongue.

[0288] Aspect 46: The method according to aspect 44 or aspect 45, wherein forming the groove along the second edge includes machining the groove.

[0289] Aspect 47: The method according to aspect 45 or aspect 46, wherein machining the first groove includes machining the first groove with a CNC machine.

[0290] Aspect 48: The method according to any one of aspects 45 to 47, wherein machining the first groove includes machining the first groove with a double-end tenoning machine.

[0291] Aspect 49: The method according to any one of aspects 44 to 48, further comprising:

[0292] Fixing the rigid core to a machining device; and

[0293] Releasing the rigid core from the machining device only after the tongue and the groove have been machined.

[0294] Aspect 50: The method according to any one of aspects 43 to 49, further comprising forming the rigid core in a mold.

[0295] Aspect 51: The method according to aspect 50, wherein forming the rigid core in the mold includes:

[0296] Heating a fiber mat for a first period of time at a first temperature; and

[0297] Subjecting the heated fiber mat to pressure with a surface of a press, wherein the surface has a surface temperature lower than the first temperature, thereby forming the at least one dense fiber mat.

[0298] Aspect 52: The method according to aspect 51, wherein the fiber mat includes a first plurality of fibers having a first melting point and a second plurality of fibers, wherein at least a portion of the second plurality of fibers has a second melting point lower than the first melting point, and wherein the first temperature is higher than the second melting point and lower than the first melting point.

[0299] Aspect 53: The method according to aspect 52, wherein at least a portion of the second plurality of fibers having the second melting point is an outer portion of the fibers.

[0300] Aspect 54: The method according to aspect 52 or aspect 53, wherein the second plurality of fibers comprises multicomponent fibers, wherein the multicomponent fibers comprise a skin and a core provided as a skin-core structure, and wherein the skin has the second melting point.

[0301] Aspect 55: The method according to aspect 54, wherein the at least one compact fiber mat comprises at least a first compact fiber mat and a second compact fiber mat, the method further comprising needling the at least one compact fiber mat to entangle the first compact fiber mat and the second compact fiber mat.

[0302] Aspect 56: The method according to aspect 55, wherein the first compact fiber mat has a first density, wherein the second compact fiber mat has a second density greater than the first density, and wherein the first compact fiber mat defines the first surface.

[0303] Although the foregoing invention has been described in detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be made within the scope of the appended claims.

Claims

1. A surface covering element (10), comprising: A rigid core (12) comprising at least one compact fiber mat (14), the rigid core comprising a first surface (16) and an opposite second surface (18) spaced apart along a first axis (4), wherein the rigid core (12) comprises a plurality of edges (20) defining the outer periphery of the rigid core; Wherein the plurality of edges (20) at least comprises a first edge (20a) and an opposite second edge (20b) spaced apart along a second axis (6) perpendicular to the first axis (4), wherein the first edge (20a) comprises a tongue (22), wherein The second edge (20b) defines a groove (24).

2. The surface covering element (10) according to claim 1, wherein the at least one compact fiber mat (14) is a plurality of layers of compact fiber mats.

3. The surface covering element (10) according to claim 2, wherein the plurality of layers of compact fiber mats at least comprises a first compact fiber mat (14a) and a second compact fiber mat (14b), wherein the first compact fiber mat (14a) has a first density, and wherein the second compact fiber mat (14b) has a second density greater than the first density.

4. The surface covering element (10) according to claim 3, wherein the first and second compact fiber mats (14a, 14b) are needled together.

5. The surface covering element (10) according to claim 3, wherein the first compact fiber mat (14a) defines the first surface (16).

6. The surface covering element (10) according to claim 3, wherein the second density is 40 lb / ft 3 to about 100 lb / ft 3 .

7. The surface covering element (10) according to claim 3, wherein the first density is 10 lb / ft 3 to 30 lb / ft 3 .

8. The surface covering element (10) according to claim 3, wherein the second compact fiber mat (14b) defines the tongue (22), and wherein a portion of the second compact fiber mat (14b) defines the groove (24).

9. The surface covering element (10) according to claim 1, wherein the at least one dense fiber mat (14) comprises a first dense fiber mat (14a) having a density of 40 lb / ft 3 to about 100 lb / ft 3 3.

10. The surface covering element (10) according to claim 1, wherein the tongue (22) has a thickness along the first axis (4), and wherein the thickness of the tongue (22) is from about 0.5 mm to about 3 mm.

11. The surface covering element (10) according to claim 8, wherein the thickness of the tongue (22) is about 1 mm.

12. The surface covering element (10) according to claim 8, wherein the first surface (16) of the rigid core (12) meets the first edge (20) at a first boundary (32) of the rigid core (12), and wherein the tongue (22) extends a protruding distance along the second axis (6) from the first boundary (32) of the rigid core (12), and wherein the protruding distance is at least 2 mm.

13. The surface covering element (10) according to claim 1, wherein the tongue (22) has opposite first and second surfaces (27, 28) spaced apart along the first axis (4), and wherein a reference plane (29) bisects the opposite first and second surfaces of the tongue (22), and wherein the reference plane forms an inclined angle with the first surface (16) of the rigid core.

14. The surface covering element (10) according to claim 1, wherein the tongue (22) has opposite first and second surfaces (27, 28) spaced apart along the first axis (4), wherein a reference plane (29) bisects the upper and lower surfaces of the tongue, and wherein the reference plane is parallel to the first surface (16) of the rigid core (12).

15. The surface covering element (10) according to claim 13, wherein the groove (26) is defined between opposite inner surfaces (34), wherein the opposite inner surfaces include first opposite portions (38), wherein a second reference plane (36) bisects the first opposite portions, and wherein the second plane forms an inclined angle with the first surface (16) of the rigid core (12).

16. The surface covering element (10) according to claim 13, wherein at least one of the opposite inner surfaces (34) defining the groove (24) includes a second portion (44) parallel to the first surface (16) of the rigid core (12).

17. The surface covering element (10) according to claim 1, wherein the tongue (22) and the groove (24) are formed by machining.

18. The surface covering element (10) according to claim 1, wherein the first and second edges (20a, 20b) include opposite ends (50), wherein the plurality of edges further includes opposite third and fourth edges (20c, 20d) extending between the respective opposite ends of the first and second edges, wherein the tongue (22) is a first tongue, wherein the groove (24) is a first groove, wherein the third edge defines a second tongue (22b), and wherein the fourth edge defines a second groove (24b).

19. The surface covering element (10) according to claim 16, wherein the first and second edges (20a, 20b) extend perpendicular or substantially perpendicular to the third and fourth edges (20c, 20d).

20. The surface covering element (10) according to claim 1, wherein the first edge (20a) has a length along a third axis (8) perpendicular to each of the first and second axes (4, 6), and wherein the length of the tongue (22) is equal to or substantially equal to the length of the first edge.

21. The surface covering element (10) according to claim 1, wherein the first edge (20a) has a length along a third axis (8) perpendicular to each of the first and second axes (4, 6), and wherein the length of the tongue is less than the length of the first edge (4).

22. The surface covering element (10) according to claim 1, wherein the groove (24) is defined by opposite legs (48), and wherein the rigid core (12) defines: at least one through-opening (52) extending along the first axis (4) through the tongue (22); and At least one through-opening (54) extending from the first surface (16) to the second surface (18) of the rigid core through the leg (48) defining the recess.

23. The surface covering element (10) according to claim 1, further comprising a decorative portion (56) having a first surface (58) and an opposite second surface (60), wherein the second surface (58) of the decorative portion is attached to the first surface (16) of the rigid core (16).

24. The surface covering element (10) according to claim 1, wherein the at least one dense fiber mat (14) comprises randomly oriented fibers.

25. The surface covering element (10) according to claim 1, wherein the at least one dense fiber mat (14) comprises substantially uniformly oriented fibers.

26. The surface covering element (10) according to claim 1, wherein the at least one dense fiber mat (14) comprises a first dense fiber mat (14a), the first dense fiber mat comprising a first plurality of fibers (62) having a first melting point and a second plurality of fibers (64), wherein at least a portion of the second plurality of fibers has a second melting point lower than the first melting point.

27. The surface covering element according to claim 26, wherein the at least a portion of the second plurality of fibers (64) having the second melting point is an outer portion (66) of the fibers of the second plurality of fibers.

28. The surface covering element (10) according to claim 1, wherein the at least one dense fiber mat (14) comprises a first dense fiber mat (14a), the first dense fiber mat comprising a first plurality of fibers (62) having a first melting point and a second plurality of fibers (64), wherein the second plurality of fibers comprises multi-component fibers, wherein the multi-component fibers comprise a skin and a core provided as a skin-core structure, and wherein the skin has a second melting point lower than the first melting point.

29. The surface covering element (10) according to claim 1, wherein the surface covering element is a floor element.

30. The surface covering element (10) according to claim 1, wherein the surface covering element is a wall covering element.

31. The surface covering element (10) according to claim 1, wherein the surface covering element is an erosion control mat.

32. The surface covering element (10) according to claim 1, wherein the rigid core (12) comprises light-transmitting fibers.

33. The surface covering element (10) according to claim 1, further comprising an adhesive (72) on the tongue.

34. The surface covering element (10) according to claim 30, further comprising a release liner (74) covering the adhesive (72).

35. The surface covering element (10) according to claim 8, wherein the second density is 40 lb / ft 3 to about 100 lb / ft 3 .

36. The surface covering element (10) according to claim 35, wherein the first density is 10 lb / ft 3 to 30 lb / ft 3 .

37. A surface covering (70) comprising: A plurality of surface covering elements (10) according to any one of the preceding claims, wherein the plurality of surface covering elements includes a first surface covering element (10a) and a second surface covering element (10b), and wherein the tongue (22) of the first surface covering element engages with the groove (24) of the second surface covering element.

38. The surface covering (70) according to claim 37, further comprising an adhesive (72) that couples the tongue of the first surface covering element to the groove of the second surface covering element.

39. The surface covering (70) according to claim 37, wherein the adhesive (72) comprises a compression-activated adhesive.

40. The surface covering (70) according to claim 37, wherein the adhesive (72) comprises an ultraviolet-activated adhesive.

41. The surface covering (70) according to claim 37, wherein the first surface covering element (10a) defines at least one through-opening (52) extending along the first axis (4) through the tongue (22), wherein the groove (24) of the second surface covering element is defined by a pair of legs (48), and wherein the second surface covering element defines at least one through-opening (54) extending from the first surface (16) to the second surface (18) of the rigid core (12) through the legs defining the groove. wherein the surface covering (70) further comprises at least one fastener (76), and each of the at least one fasteners extends through each of the following: one of the at least one through-openings extending through the tongue of the first surface covering element; and one of the at least one through-openings extending through the legs defining the groove.

42. A method of assembling a surface covering (70) that includes a plurality of surface covering elements (10) according to any one of claims 1 to 36, the plurality of surface covering elements including at least a first surface covering element (10a) and a second surface covering element (10b), the method comprising: Inserting the tongue (22) of the first surface covering element (10a) into the groove (24) of the second surface covering element (10b).

43. The method according to claim 42, further comprising adhering the tongue (22) of the first surface covering element (10a) to the groove (24) of the second surface covering element (10b).

44. The method according to claim 43, wherein adhering the tongue (22) of the first surface covering element (10a) to the groove (22) of the second surface covering element comprises activating an ultraviolet-activated adhesive with ultraviolet radiation.

45. A method that includes: A tongue (22) is formed along a first edge (20a) of a rigid core (12), wherein the rigid core includes at least one dense fiber mat (14), the dense fiber mat including a first surface (16) and an opposite second surface (18) spaced apart along a first axis (4), wherein the rigid core (12) includes a plurality of edges (20) defining an outer perimeter of the rigid core, the plurality of edges including at least the first edge and an opposite second edge (20b) spaced apart along a second axis (6) perpendicular to the first axis.

46. The method according to claim 45, further comprising: forming a groove (24) along the second edge.

47. The method according to claim 45, wherein forming the tongue (22) along the first edge (20a) includes machining the tongue.

48. The method according to claim 46, wherein forming the groove (24) along the second edge (20b) includes machining the groove.

49. The method according to claim 48, wherein machining the groove (24) includes machining the groove with a CNC machine.

50. The method according to claim 48, wherein machining the groove (24) includes machining the groove with a double-end tenoning machine.

51. The method according to claim 46, further comprising: fixing the rigid core (12) to a machining device; and releasing the rigid core from the machining device only after the tongue (22) and the groove (24) have been machined.

52. The method according to claim 45, further comprising forming the rigid core (12) in a mold.

53. The method according to claim 52, wherein forming the rigid core (12) in the mold includes: heating a fiber mat (80) for a first period of time at a first temperature; and subjecting the heated fiber mat to pressure with a surface (84) of a press (82), wherein the surface has a surface temperature less than the first temperature, thereby forming the at least one dense fiber mat.

54. The method according to claim 53, wherein the fiber mat (12) includes a first plurality of fibers (62) having a first melting point and a second plurality of fibers (74), wherein at least a portion of the second plurality of fibers has a second melting point lower than the first melting point, wherein the first temperature is higher than the second melting point and lower than the first melting point.

55. The method according to claim 54, wherein the at least a portion of the second plurality of fibers (64) having the second melting point is an outer portion (66) of the fibers.

56. The method according to claim 54, wherein the second plurality of fibers (64) includes multi-component fibers, wherein the multi-component fibers include a skin and a core provided as a skin-core structure, and wherein the skin has the second melting point.

57. The method according to claim 56, wherein the at least one compacted fibrous mat (14) comprises at least a first compacted fibrous mat (14a) and a second compacted fibrous mat (14b), and the method further comprises needling the at least one compacted fibrous mat to entangle the first compacted fibrous mat and the second compacted fibrous mat.

58. The method according to claim 57, wherein the first compacted fibrous mat (14a) has a first density, wherein the second compacted fibrous mat (14b) has a second density greater than the first density, and wherein the first compacted fibrous mat defines the first surface (16).

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