Thermoplastic planks and methods for making the same

• US 8,021,741 B2
• Filed: 06/29/2010
• Issued: 09/20/2011
• Est. Priority Date: 12/14/1999
• Status: Expired due to Fees

• Current Assignee: Valinge Innovation AB
• Original Assignee: Mannington Mills Incorporated (Mannington Commercial Incorporated)
• Inventors: Judd, Richard, Chen, Hao A.
• Primary Examiner(s): Watkins, III; William P
• Application Number:
  US12/825,447
• Publication Number:
  US 20100260962A1
• Time in Patent Office: 448 Days
• Field of Search: 428/195.1, 428/44, 428/166, 428/148, 428/149, 428/178, 428/201, 428/203, 428/204, 428/46, 428/503, 523/091, 525/861
• US Class Current: 428/195.1
• CPC Class Codes: B29C 2795/007 after shaping
• CPC Class Codes: B29C 48/001 Combinations of extrusion moulding with other shaping operations
• 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 48/304 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29C 59/02 by mechanical means, e.g. pressing B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/30325 making use of cavities belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/435 Making large sheets by joining smaller ones or strips together
• 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 66/7315 : Mechanical properties
• CPC Class Codes: B29C 66/73151 : Hardness
• CPC Class Codes: B29K 2021/00 : Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2023/065 : HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/00 : Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain , not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
• CPC Class Codes: B29K 2995/007 : Hardness
• CPC Class Codes: B29K 2995/0089 : Impact strength or toughness
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2024/006 : multi-channelled
• CPC Class Codes: B29L 2031/732 : Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: B32B 2255/10 : on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2260/028 : Paper layer
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2307/31 : Heat sealable
• CPC Class Codes: B32B 2307/7246 : Water vapor barrier
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2419/04 : Tiles for floors or walls
• CPC Class Codes: B32B 2451/00 : Decorative or ornamental articles
• 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 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 29/06 : specially treated, e.g. surfaced, parchmentised
• 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 5/18 : characterised by features of a layer of foamed material
• 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 15/02038 : characterised by tongue and groove connections between neighbouring flooring elements
• 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 15/107 : composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04
• CPC Class Codes: E04F 2201/05 : Separate connectors or inserts, e.g. pegs, pins, keys or strips
• CPC Class Codes: E04F 2201/0511 : Strips or bars, e.g. nailing strips
• CPC Class Codes: E04F 2201/0529 : the interlocking key acting as a dovetail-type key
• CPC Class Codes: E04F 2203/04 : comprising a plurality of internal elongated cavities arranged in substantially parallel rows
• 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 428/17 : Three or more coplanar interfitted sections with securing means
• CPC Class Codes: Y10T 428/24008 : including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24413 : Metal or metal compound
• CPC Class Codes: Y10T 428/24421 : Silicon containing
• CPC Class Codes: Y10T 428/24562 : Interlaminar spaces
• CPC Class Codes: Y10T 428/24661 : Forming, or cooperating to form cells
• 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 428/31866 : Impregnated or coated cellulosic material

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 laminate plank comprising:

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

a print layer optionally with an underlay layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprising a printed design; and

a protective layer affixed to said top surface of said print layer, wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture,

wherein said core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm, and wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, wherein said at least one flexible thermoplastic material is flexible polyvinyl chloride, wherein said flexible thermoplastic material has a molecular weight as reflected by an inherent viscosity of from about 0.88 to about 1.0 inherent viscosity, and

wherein said print layer is a thermoplastic film with a printed design, and

wherein said protective layer comprises a polyurethane coating with or without wear resistant particles in the polyurethane coating, and

wherein said core further comprises at least one plasticizer and filler, wherein said plasticizer is present in an amount of less than about 20% by weight of said core.

32. The plank of claim 1, wherein said underlay layer is present and located and affixed between the top surface of said core and bottom surface of said print layer.

37. The plank of claim 1, further comprising a thermoplastic layer on the top surface of said core.

2. A thermoplastic laminate plank comprising:

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

a print layer optionally with an underlay layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprising a printed design; and

a protective layer affixed to said top surface of said print layer, wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture,

wherein said core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm, and wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, wherein said at least one flexible thermoplastic material is flexible polyvinyl chloride, wherein said flexible thermoplastic material has a molecular weight as reflected by an inherent viscosity of from about 0.88 to about 1.0 inherent viscosity.

3. The plank of claim 2, further comprising said underlay layer located and affixed between said bottom surface of said print layer and said top surface of said core.

4. The plank of claim 2, wherein said core further comprises at least one plasticizer and filler.

5. The thermoplastic laminate plank of claim 2, wherein said groove design has an internal depth dimension of from about 5 mm to about 12 mm and a height of from about 3 mm to about 5 mm.

6. The thermoplastic laminate plank of claim 2, wherein said thermoplastic laminate plank is suitable for outdoor installation.

7. The thermoplastic laminate plank of claim 2, wherein said thermoplastic laminate plank has a growth in width and length of 0.03% or less when thermoplastic laminate plank is exposed to 90°

F. and 100% RH.

8. The plank of claim 2, wherein said protective layer comprises aluminum oxide.

9. The plank of claim 2, wherein said protective layer comprises an aminoplast resin impregnated overlay paper.

10. The thermoplastic laminate of claim 2, wherein said thermoplastic material comprises at least one thermoplastic resin, at least one processing aid, at least one impact modifier, at least one lubricant, and at least one stabilizer.

11. A surface covering comprising a plurality of thermoplastic laminate planks of claim 2 joined together.

12. The surface covering of claim 11, wherein said surface covering is a floor covering that is a floating floor installation.

14. The thermoplastic laminate plank of claim 2, wherein said print layer is a thermoplastic film with a printed design.

15. The thermoplastic laminate plank of claim 2, wherein said print layer is a PVC film with a printed design.

16. The thermoplastic laminate plank of claim 2, wherein said thermoplastic laminate plank is dimensionally stable.

17. The thermoplastic laminate plank of claim 4, wherein said filler is calcium carbonate.

18. The thermoplastic laminate plank of claim 2, wherein one or more edges of said thermoplastic laminate plank are tapered or beveled.

19. The thermoplastic laminate plank of claim 2, wherein said protective layer includes wear resistant particles.

20. The thermoplastic laminate plank of claim 2, wherein said polyvinyl chloride is suspension grade or mass polymerization grade.

21. The surface covering of claim 11, wherein said thermoplastic laminate planks are bonded with THF at the edges.

23. The thermoplastic laminate plank of claim 2, wherein said protective layer comprises a polyurethane coating with or without wear resistant particles in the polyurethane coating.

24. The thermoplastic laminate plank of claim 2, wherein said core further comprises at least one plasticizer and filler, wherein said plasticizer is present in an amount of less than about 20% by weight of said core.

30. The plank of claim 2, wherein said protective layer is from about 10 to about 20 mil thick.

31. The plank of claim 2, wherein said protective layer is one or more wear layers.

33. The plank of claim 2, wherein said underlay layer is present and located and affixed between the top surface of said core and bottom surface of said print layer.

38. The plank of claim 2, further comprising a thermoplastic layer on the top surface of said core.

13. A thermoplastic laminate plank comprising:

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

a print layer optionally with an underlay layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprising a printed design; and

a protective layer affixed to said top surface of said print layer, wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture, wherein said core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm, and wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, wherein said at least one thermoplastic material is flexible polyvinyl chloride, and wherein said thermoplastic laminate plank has a growth in width and length of 0.03% or less when thermoplastic laminate plank is exposed to 90°

F. and 100% RH, wherein said thermoplastic material has a molecular weight as reflected by an inherent viscosity of from about 0.88 to about 1.0 inherent viscosity.

25. The thermoplastic laminate plank of claim 13, wherein said protective layer comprises a polyurethane coating with or without wear resistant particles in the polyurethane coating.

26. The thermoplastic laminate plank of claim 13, wherein said core further comprises at least one plasticizer and filler, wherein said plasticizer is present in an amount of less than about 20% by weight of said core.

34. The plank of claim 13, wherein said underlay layer is present and located and affixed between the top surface of said core and bottom surface of said print layer.

39. The plank of claim 13, further comprising a thermoplastic layer on the top surface of said core.

22. A thermoplastic laminate plank comprising:

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

a print layer optionally with an underlay layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprising a printed design; and

a protective layer affixed to said top surface of said print layer, wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture, wherein said core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm, and wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, wherein said at least one flexible thermoplastic material is flexible polyvinyl chloride, wherein said flexible thermoplastic material has a molecular weight as reflected by an inherent viscosity of from about 0.88 to about 1.0 inherent viscosity,

wherein said thermoplastic laminate plank has a growth in width and length of 0.03% or less when thermoplastic laminate plank is exposed to 90°

F. and 100% RH, and

wherein said print layer is a thermoplastic film with a printed design.

27. The thermoplastic laminate plank of claim 22, wherein said protective layer comprises a polyurethane coating with or without wear resistant particles in the polyurethane coating.

28. The thermoplastic laminate plank of claim 22, wherein said plasticizer is present in an amount of less than about 20% by weight of said core.

35. The plank of claim 22, wherein said underlay layer is present and located and affixed between the top surface of said core and bottom surface of said print layer.

40. The plank of claim 22, further comprising a thermoplastic layer on the top surface of said core.

29. A thermoplastic laminate plank comprising:

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

a print layer optionally with an underlay layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprising a printed design; and

a protective layer affixed to said top surface of said print layer, wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture,

wherein said core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm, and wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, wherein said at least one flexible thermoplastic material is flexible polyvinyl chloride, wherein said flexible thermoplastic material has a molecular weight as reflected by an inherent viscosity of from about 0.88 to about 1.0 inherent viscosity, and

wherein said print layer is a thermoplastic film with a printed design.

36. The plank of claim 29, wherein said underlay layer is present and located and affixed between the top surface of said core and bottom surface of said print layer.

41. The plank of claim 29, further comprising a thermoplastic layer on the top surface of said core.