Thermoplastic planks and methods for making the same

• US 7,169,460 B1
• Filed: 08/01/2000
• Issued: 01/30/2007
• Est. Priority Date: 12/14/1999
• Status: Expired due to Term

• Current Assignee: Valinge Innovation AB
• Original Assignee: Mannington Mills Incorporated (Mannington Commercial Incorporated)
• Inventors: Chen, Hao A., Judd, Richard
• Primary Examiner(s): Watkins, III; William P.
• Application Number:
  US09/630,121
• Time in Patent Office: 2,373 Days
• Field of Search: 428/195, 428/195.1, 428/166, 428/201, 428/203, 428/204, 428/46, 428/409, 428/514, 427/261, 427/267, 525/861, 523/091
• US Class Current: 428/195.1
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/11 comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/17 the components having different colours
• CPC Class Codes: B29C 48/19 the layers being joined at their edges
• CPC Class Codes: B29C 48/20 one of the layers being a strip, e.g. a partially embedded strip
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 66/543 joining more than two hollow-preforms to form said hollow articles
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/72328 Paper
• CPC Class Codes: B29C 66/72329 Wood
• CPC Class Codes: B29C 66/72343 for liquids
• CPC Class Codes: B29C 66/7315 Mechanical properties
• CPC Class Codes: B29C 66/73151 Hardness
• CPC Class Codes: B29C 66/73161 Roughness or rugosity
• CPC Class Codes: B29K 2023/0633 LDPE, i.e. low density polyethylene
• CPC Class Codes: B29K 2023/065 HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2023/14 Copolymers of polypropylene B29K2023/16 takes precedence
• CPC Class Codes: B29K 2025/06 : PS, i.e. polystyrene
• CPC Class Codes: B29K 2025/08 : Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene B29K2055/02 takes precedence
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2029/04 : PVOH, i.e. polyvinyl alcohol B29K2031/04 takes precedence
• CPC Class Codes: B29K 2031/04 : Polymers of vinyl acetate, e.g. PVAc, i.e. polyvinyl acetate
• CPC Class Codes: B29K 2033/08 : Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: B29K 2055/02 : ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/06 : Unsaturated polyesters
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/12 : PPO, i.e. polyphenylene oxide; PPE, i.e. polyphenylene ether
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/08 : PI, i.e. polyimides or derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2995/007 : Hardness
• CPC Class Codes: B29K 2995/0089 : Impact strength or toughness
• CPC Class Codes: B29L 2024/006 : multi-channelled
• CPC Class Codes: B32B 2260/028 : Paper layer
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2317/125 : impregnated with thermosetting resin
• 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 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• 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 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04F 15/02033 : Joints with beveled or recessed upper edges
• CPC Class Codes: E04F 15/02172 : Floor elements with an anti-skid main surface, other than with grooves
• 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 2201/0511 : Strips or bars, e.g. nailing strips
• CPC Class Codes: E04F 2201/0523 : Separate tongues; Interlocking keys, e.g. joining mouldings of circular, square or rectangular shape
• CPC Class Codes: E04F 2201/0529 : the interlocking key acting as a dovetail-type key
• CPC Class Codes: Y10T 403/559 : Fluted or splined section
• CPC Class Codes: Y10T 428/16 : Two dimensionally sectional layer
• CPC Class Codes: Y10T 428/162 : Transparent or translucent layer or section
• CPC Class Codes: Y10T 428/18 : Longitudinally sectional layer of three or more sections
• CPC Class Codes: Y10T 428/24413 : Metal or metal compound
• CPC Class Codes: Y10T 428/24421 : Silicon containing
• CPC Class Codes: Y10T 428/24479 : including variation in thickness
• CPC Class Codes: Y10T 428/24562 : Interlaminar spaces
• CPC Class Codes: Y10T 428/2457 : Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24661 : Forming, or cooperating to form cells
• CPC Class Codes: Y10T 428/24777 : Edge feature
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24868 : Translucent outer layer
• CPC Class Codes: Y10T 428/24876 : Intermediate layer contains particulate material [e.g., pigment, etc.]
• CPC Class Codes: Y10T 428/31 : Surface property or characteristic of web, sheet or block
• CPC Class Codes: Y10T 428/31866 : Impregnated or coated cellulosic material
• CPC Class Codes: Y10T 428/31906 : Ester, halide or nitrile of addition polymer

Abstract

A thermoplastic laminate plank is described wherein the thermoplastic laminate plank comprises a core, a print layer, and optionally an overlay. The core comprises at least one thermoplastic material and has a top surface and bottom surface wherein a print layer is affixed to the top surface of the core and an overlay layer is affixed to the top surface of the print layer. Optionally, an underlay layer can be located and affixed between the bottom surface of the print layer and the top surface of the core. In addition, a method of making the thermoplastic laminate plank is further described which involves extruding at least one thermoplastic material into the shape of the core and affixing a laminate on the core, wherein the laminate comprises an overlay affixed to the top surface of the print layer and optionally an underlay layer affixed to the bottom surface of the print layer.

Claims

1. A thermoplastic plank comprising:

a core comprising at least one thermoplastic material wherein said core has a top surface, a bottom surface, and opposing sides;

a digital printed design on said top surface of the plank;

at least one protective coating on top of said digital printed design,

wherein said thermoplastic material comprises at least one thermoplastic resin, at least one processing aid, at least one impact modifier, at least one lubricant, at least one stabilizer, and at least one plasticizer, wherein said plasticizer is present in an amount of less than about 20% by weight of said core;

said core has a thickness of from about 5 mm to about 20 mm and a width of from about 2 cm to about 30 cm;

said core has a series of paralleled cavities which are separated by said thermoplastic material;

said core has at least one groove located on a side of said core; and

wherein said core has a surface tension of at least 34 dynes/cm.

2. The plank of claim 1, wherein said core is a rigid thermoplastic material.

3. The plank of claim 1, wherein said at least one thermoplastic material is polyvinyl chloride.

4. The plank of claim 1, wherein said at least one thermoplastic material is a rigid polyvinyl chloride.

5. The plank of claim 1, wherein said core has a length of from about 30 cm to about 130 cm.

6. The plank of claim 1, wherein said series of cavities are rounded, triangular, or rectangular in cross-section.

7. The plank of claim 1, wherein each of said series of cavities includes a dimension of about 0.3 inch by about 0.3 inch and is separated by said thermoplastic material having a thickness of from about 0.05 inch to about 0.07 inch.

8. The plank of claim 1, wherein said core has a groove located on two sides of said core, wherein said sides are opposite to each other.

9. The plank of claim 1, wherein said grooves have teeth located on the upper surface, lower surface, or both upper and lower surfaces of said grooves.

10. The plank of claim 1, wherein two sides of said core are tapered or have beveled edges, wherein said sides are opposite to each other.

11. The plank of claim 1, wherein said bottom surface of said core has at least two bottom feet or a series of coextruded polymeric strips to raise said core from a sub-floor or substrate surface.

12. The thermoplastic plank of claim 1, wherein said protective coating comprises a polyurethane type coating with or without wear resistant particles in the coating.

13. The thermoplastic plank of claim 1, wherein said thermoplastic material comprises polyvinyl chloride type polymers.

14. The thermoplastic laminate of claim 1, wherein said thermoplastic material further comprises at least one pigment.

15. The thermoplastic plank of claim 1, said plank having a substantially planar top surface, opposing sides, opposing ends, and a bottom surface, wherein said bottom surface has a plurality of channels formed therein, each of said channels extending longitudinally from one end of the plank to the other end of the plank.

16. The thermoplastic flooring plank of claim 15, wherein said channels are substantially U-shaped.

17. A flooring system comprising a plurality of the thermoplastic flooring planks of claim 15 connected together.

18. The thermoplastic plank of claim 1, said plank having substantially planar top and bottom surfaces, opposing ends, and a series of elongate cavities between said top and bottom surfaces, each of said cavities extending from one of said opposing ends of said plank to another of said opposing ends of said plank.

19. A flooring system comprising a plurality of the thermoplastic flooring planks of claim 18 connected together.

20. A surface covering comprising a plurality of thermoplastic planks of claim 1 joined together.

21. The surface covering of claim 20, wherein said surface covering is a floor covering that is a floating floor installation.

29. The thermoplastic plank of claim 1, wherein no filler is present in said core.

30. The thermoplastic plank of claim 1, wherein said core has a surface tension of at least 45 dynes/cm.

31. The thermoplastic plank of claim 1, wherein said core has a surface tension of 34 dynes/cm to 45 dynes/cm.

22. A floor covering comprising a plurality of thermoplastic planks, wherein said floor covering is a floating surface and wherein said thermoplastic plank comprises:

a core comprising at least one thermoplastic material, wherein each core has a top surface and a bottom surface, and opposing sides;

a digital printed design on said top surface of said core, wherein said digital printed design has a top surface and a bottom surface;

a protective layer affixed to said top surface of said digital printed design,

wherein said thermoplastic material comprises at least one thermoplastic resin, at least one processing aid, at least one impact modifier, at least one lubricant, at least one stabilizer, and at least one plasticizer, wherein said plasticizer is present in an amount of less than about 20% by weight of said core;

said core has a thickness of from about 5 mm to about 20 mm and a width of from about 2 cm to about 30 cm;

said core has a series of paralleled cavities which are separated by said thermoplastic material;

said core has at least one groove located on a side of said core; and

wherein said core has a surface tension of at least 34 dynes/cm.

23. The floor covering of claim 22, wherein at least a portion of said thermoplastic laminate planks are joined together by splines.

24. The floor covering of claim 22, wherein at least a portion of said thermoplastic laminate planks are joined together by a bonding agent.

25. The floor covering of claim 24, wherein said bonding agent is tetrahydrofuran methylene chloride, a ketone, or combinations thereof.

26. A thermoplastic plank comprising:

a core comprising at least one thermoplastic material, wherein said core has a top surface and a bottom surface, and opposing sides;

a digital printed design on said top surface of said core, wherein said digital printed design has a top surface and a bottom surface;

at least one protective layer affixed to said top surface of said digital printed design, with the proviso that no backing layer is located adjacent the bottom surface of said core,

wherein said thermoplastic material comprises at least one thermoplastic resin, at least one processing aid, at least one impact modifier, at least one lubricant, at least one stabilizer, and at least one plasticizer, wherein said plasticizer is present in an amount of less than about 20% by weight of said core;

said core has a thickness of from about 5 mm to about 20 mm and a width of from about 2 cm to about 30 cm;

said core has a series of paralleled cavities which are separated by said thermoplastic material;

said core has at least one groove located on a side of said core; and

wherein said core has a surface tension of at least 34 dynes/cm.

27. The thermoplastic plank of claim 26, wherein each core has a series of parallel cavities which are separated by said thermoplastic material, wherein the thickness of the thermoplastic material separating the outermost cavities is thicker than the thickness of the thermoplastic material separating the innermost cavities.

32. The thermoplastic plank of claim 26, wherein said core has a surface tension of at least 45 dynes/cm.

33. The thermoplastic plank of claim 26, wherein said core has a surface tension of 34 dynes/cm to 45 dynes/cm.

28. A thermoplastic plank comprising:

a core comprising at least one thermoplastic material, wherein said core has a top surface and a bottom surface, and opposing sides;

a digital printed design on said top surface of said core, wherein said digital printed design has a top surface and a bottom surface;

a protective layer affixed to said top surface of said digital printed design, wherein said at least bottom surface of the core is thermally treated,

wherein said thermoplastic material comprises at least one thermoplastic resin, at least one processing aid, at least one impact modifier, at least one lubricant, at least one stabilizer, and at least one plasticizer, wherein said plasticizer is present in an amount of less than about 20% by weight of said core;

said core has a thickness of from about 5 mm to about 20 mm and a width of from about 2 cm to about 30 cm;

said core has a series of paralleled cavities which are separated by said thermoplastic material;

said core has at least one groove located on a side of said core; and

wherein said core has a surface tension of at least 34 dynes/cm.

34. The thermoplastic plank of claim 28, wherein said core has a surface tension of at least 45 dynes/cm.

35. The thermoplastic plank of claim 28, wherein said core has a surface tension of 34 dynes/cm to 45 dynes/cm.