Patent ID: 7820095

Claim:
A method for forming a floor tile comprising: mixing a hardener into a base epoxy resin to form a binder; blending about 40 weight percent to about 80 weight percent of a low density additive including hollow microspheres having a density of about 0.3 to about 0.5 g/cc into about 20 weight percent to less than about 60 weight percent of the binder to form a slurry; pouring the slurry into a mold; moving the mold to ensure distribution of the hollow microspheres in the slurry; curing the slurry to form the floor tile so that the floor tile has the hollow microspheres dispersed throughout and a portion of the hollow microspheres form a portion of an outer surface of the floor tile; and wherein the low density additive is effective such that the outer surface of the floor tile has a temperature of about 100° F. or less upon exposure to an energy source.