Coated synthetic resin board tiles

• US 5,976,689 A
• Filed: 11/14/1996
• Issued: 11/02/1999
• Est. Priority Date: 03/20/1995
• Status: Expired due to Fees

• Current Assignee: Prism Enterprises LP (The Cooper Cos., Inc.)
• Original Assignee: PermaGrain Products, Inc.
• Inventors: Humphreys, Matthew F., Tomasko, Joseph E., Witt, Alvin E.
• Primary Examiner(s): Hess, Bruce H.
• Assistant Examiner(s): Bahta, Abraham
• Application Number:
  US08/749,939
• Time in Patent Office: 1,083 Days
• Field of Search: 428/908.8, 428/172, 428/44, 428/48, 428/192, 428/240, 428/423.1, 428/521, 428/339, 428/67, 428/304.4, 156/60, 156/61, 156/64, 156/72, 156/73.4, 156/244.17, 156/244.19
• US Class Current: 428/339
• CPC Class Codes: B27D 1/00 Joining wood veneer with any material; Forming articles thereby in conjunction with moulding of wood particles or fibres B27N3/06; Preparatory processing of surfaces to be joined, e.g. scoring
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/026 Wood layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/16 Two dimensionally sectional layer
• CPC Class Codes: Y10T 428/164 Continuous two dimensionally sectional layer
• CPC Class Codes: Y10T 428/22 Nonparticulate element embedded or inlaid in substrate and visible
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31931 : Polyene monomer-containing
• CPC Class Codes: Y10T 442/3862 : Ester condensation polymer sheet or film [e.g., polyethylene terephthalate, etc.]

Abstract

A method of making coated synthetic resin tile. A resin admixture is formed and cured to form a tile base. The tile base is sized and gauged to a desired size, followed by mating an upper veneer layer on the tile. The upper layer is selected from the group consisting of an acrylic impregnated wood veneer and a hardwood veneer having a vinyl upper layer. The veneer is bonded to the tile base with a fabric and an adhesive and pressure. The veneer mated tile is then sized to a final desired tile size and configuration.

Claims

1. A coated synthetic resin tile, comprising:

a moisture impervious base portion comprising a thermoset or thermoplastic resin; and

a veneer upper layer bonded to said base portion with a polyurethane adhesive, said upper veneer layer being selected from the group consisting of an acrylic impregnated wood veneer or a hardwood veneer having a protective coating.

2. A coated synthetic resin tile, comprising:

a moisture impervious base portion comprising a thermoset or thermoplastic resin;

a fabric of glass fibers overlying said base layer impregnated with and bonded to said base layer by a polyurethane adhesive;

a veneer upper layer bonded to said base portion with an adhesive, said upper veneer layer being selected from the group consisting of an acrylic impregnated wood veneer or a hardwood veneer having a vinyl protective coating.

3. A coated synthetic resin tile, comprising:

a moisture impervious base portion formed from about 20%-30% by weight of a flexible resin selected from the group of flexible unsaturated polyester resin and a rigid resin selected from the group of rigid unsaturated polyester resin, said resins being cross linked and an aluminum trihydrate flame retardant of about 50%-75% by weight;

the aluminum trihydrate having a surface treatment to provide a tight packed hydrophobic base; and

a veneer upper layer bonded to said base portion with an adhesive, said upper veneer layer being selected from the group consisting of an acrylic impregnated wood veneer or a hardwood veneer having a vinyl protective coating.

4. A coated synthetic resin tile, comprising a base portion and a veneer:

said base comprising a moisture impervious material of a thermoset or thermoplastic resin;

a filler of up to about 10% calcium carbonate of about 4 micron particulate size and an aluminum trihydrate flame retardant of about 60%-70% of about 50 micron particulate size and an aluminum trihydrate of about 20%-40% of about 9 micron particulate size aluminum trihydrate in order to provide a class A flame spread rating; and

said veneer comprising a layer selected from the group consisting of an acrylic impregnated wood veneer and a hardwood veneer having a vinyl upper layer bonded to said base portion with a polyurethane adhesive.