Floor Panel Containing A Polymer And Cork

• US 20100319282A1
• Filed: 06/21/2010
• Published: 12/23/2010
• Est. Priority Date: 06/22/2009
• Status: Active Grant

• Current Assignee: Novalis Holdings Limited (Cognizant Technology Solutions Corp.)
• Original Assignee: Novalis Holdings Limited (Cognizant Technology Solutions Corp.)
• Inventors: Ruland, Carl
• Granted Patent: US 8,474,208 B2
• Time in Patent Office: Days
• US Class Current: 52/309.3
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2264/06 Vegetal particles
• CPC Class Codes: B32B 2266/0221 Vinyl resin
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/302 Conductive
• CPC Class Codes: B32B 2307/306 Resistant to heat
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/22 : using plasticisers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/022 : Mechanical properties
• CPC Class Codes: C08L 2666/02 : Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 : Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 27/06 : Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 97/007 : Cork
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04F 15/10 : of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: E04F 2201/0138 : by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: Y10T 428/14 : Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1486 : Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/3167 : Of cork

Abstract

A vinyl floor panel for a flooring system prepared from a blend of a polymer and cork granules. The floor panel includes top and bottom surfaces with a first layer between both surfaces. A printed pattern is located on the top surface. The first layer is prepared from a blend of a polymer polyvinyl chloride and cork granules, where the cork granules are evenly distributed with the polyvinyl chloride throughout the length, width, and thickness of the first layer.

Claims

1. A floor panel, comprising:

a top and bottom surface, the top surface having a printable pattern; and

a first layer prepared from a blend of a polymer and cork granules, the cork granules evenly distributed with polyvinyl chloride through the length, width, and thickness of the first layer.

2. The floor panel according to claim 1, wherein the blend is a homogenous blend.

3. The floor panel according to claim 1, wherein the polymer is polyvinyl chloride.

4. The floor panel according to claim 3, wherein the polyvinyl chloride is a resin.

5. The floor panel according to claim 1, wherein the cork granules have a thickness of about 0.03-0.3 mm.

6. The floor panel according to claim 1, wherein the first layer is a composition of about 100 parts of polyvinyl chloride and about 15-150 parts of cork granules.

7. The floor panel according to claim 6, wherein the first layer further includes about 40-120 parts of plasticizer.

8. The floor panel according to claim 5, wherein the first layer thickness is about 1.5-2.7 mm.

9. The floor panel according to claim 1, further comprising a second layer of flexible polymeric material and a third layer prepared from a rigid polymeric material, the second and third layers positioned on opposite surfaces of the first layer.

10. The floor panel according to claim 9, wherein the second layer includes a thin coating layer, a durable wear layer and an ornamental layer having printed features.

11. The floor panel according to claim 10, wherein the thin coating layer, the durable wear layer or the ornamental layer is textured.

12. The floor panel according to claim 10, wherein the ornamental layer is positioned on the surface of the first layer, the printed features facing away from the third layer.

13. The floor panel according to claim 9, wherein third layer is a uniform layer of high density plastic.

14. The floor panel according to claim 9, wherein the bottom layer includes a fastening source that maintains connection between the floor panel and an adjacent floor panel or a surface of a floor.

15. The floor panel according to claim 1, further comprising a fastening source.

16. The floor panel according to claim 15, wherein the fastening source is a pre-applied adhesive.

17. The floor panel according to claim 15, wherein the fastening source is a locking system.

18. A method of making a blank, comprising the steps of:

mixing a dry blend of polyvinyl chloride resin and the cork granules;

adding a plasticizer to the dry blend;

heating the blend of polyvinyl chloride resin, cork granules, and plasticizer to produce a homogenous vinyl foam;

preparing a layer of homogenous vinyl foam having a length, height and width; and

distributing the cork granules throughout the length, height and width.

19. The method of making a blank according to claim 18, further comprising the steps of:

positioning a second layer of material on a surface of the layer of homogenous vinyl foam; and

hot pressing the layer of homogenous vinyl foam and the second layer together.

20. The method of making a blank according to claim 19, wherein the second layer is a backing layer.

21. The method of making a blank according to claim 18, further comprising the steps of:

preparing a fastening source on a bottom surface of the backing layer.

22. The method of making a blank according to claim 18, further comprising the steps of:

positioning a third layer of material on an opposite surface of the layer of homogenous vinyl foam; and

hot pressing the layer of homogenous vinyl foam, second layer, and third layer together.

23. The method of making a blank according to claim 22, wherein the third layer is a top layer.

24. The method of making a blank according to claim 23, wherein the top layer includes a durable wear layer and an ornamental layer which are pre-bonded before hot pressing the top and layer of homogenous vinyl foam.

25. The method of making a blank according to claim 18, wherein the dry blend is a composition of about 100 parts polyvinyl chloride and about 15-150 parts cork particles.

26. The method of making a blank according to claim 18, wherein the cork particles have a thickness of about 0.03-0.3 mm and a water content of less than about 3% before about 40-120 parts of plasticizer are added to the dry blend.