Coated synthetic resin board tiles

• US 5,985,397 A
• Filed: 11/14/1997
• Issued: 11/16/1999
• Est. Priority Date: 03/20/1995
• Status: Expired due to Fees

• Current Assignee: Alvin E. Witt, Joseph E. Tomasko, Matthew F. Humphreys
• Original Assignee: Alvin E. Witt, Joseph E. Tomasko, Matthew F. Humphreys
• Inventors: Witt, Alvin E., Humphreys, Matthew F., Tomasko, Joseph E.
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): Bahta, Abraham
• Application Number:
  US08/970,370
• Time in Patent Office: 732 Days
• Field of Search: 428/172, 428/908.8, 428/44, 428/48, 428/49, 428/192, 428/423.1, 428/330, 428/304.4, 428/87, 156/61, 156/60, 156/64, 156/72, 156/73.4, 156/244.17
• US Class Current: 428/44
• 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: 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 428/166 Glass, ceramic, or metal sections [e.g., floor or wall tile, etc.]
• CPC Class Codes: Y10T 428/23921 With particles
• 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.]

Abstract

A coated synthetic resin tile comprising a base portion and a veneer said base comprising a moisture impervious material such as a thermoset or thermoplastic resin. A filler of up to about 10% calcium carbonate having a 2 (two) sigma particle size between about 5.11 and 6.18 microns and an aluminum trihydrate flame retardant of about 60%-70% having a two (2) sigma particle size of between about 42.38 and 58.72 microns and an aluminum trihydrate of about 20%-40% having a two (2) sigma particle size of between about 8.26 and 9.68 microns to provide a class A flame spread rating. The 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.

Claims

1. A coated synthetic resin tile, comprising:

a moisture impervious and fire resistant 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 formed from about 20%-30% by weight of total resin 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 a aluminum trihydrate flame retardant of about 50%-75% by weight;

the flame retardant having a surface treatment to provide a tightly 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.

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

said base comprising a moisture impervious material;

a calcium carbonate filler of up to about 10% by weight of the total filler and flame retardant and having a 2 (two) sigma particle size between about 5.11 and 6.18 microns and an aluminum trihydrate flame retardant of about 60%-70% by weight of the total filler and flame retardant and having a two (2) sigma particle size of between about 42.38 and 58.72 microns and an aluminum trihydrate of about 20%-40% by weight of the total filler and flame retardant and having a two (2) sigma particle size of between about 8.26 and 9.68 microns 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.

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

said base comprising a moisture impervious material;

a calcium carbonate filler of up to about 10% by weight of the total filler and flame retardant and of about 4 micron particulate size and an aluminum trihydrate flame retardant of about 60%-70% by weight of the total filler and flame retardant and of about 50 micron particulate size and an aluminum trihydrate of about 20%-40% by weight of the total filler and flame retardant and of about 9 micron particulate size aluminum trihydrate 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.

5. The tile of claim 4 further comprising a fabric of glass fibers underlying said base layer on the side opposite said upper veneer layer, impregnated with and bonded to said base portion by a polyurethane adhesive.

6. The tile of claim 4 wherein the said resin is selected from polyester resins and polyurethane resins.