AU2020201533A1

AU2020201533A1 - Engineered Composite Flooring and Wall Covering Planks

Info

Publication number: AU2020201533A1
Application number: AU2020201533A
Authority: AU
Inventors: Zhihui Ding; Daniel Lyne
Original assignee: Hq Wood Pty Ltd
Current assignee: Hq Wood Pty Ltd
Priority date: 2019-07-15
Filing date: 2020-03-02
Publication date: 2021-02-04

Abstract

Embodiments of the present disclosure provides engineered composite planks for use in flooring and wall covering. An engineered composite plank includes a composite core comprising stone dust, Poly Vinyl Chloride (PVC), and additives. Further, the engineered composite plank includes a veneer layer adhered on a top surface of the composite core. The engineered composite plank also includes an ultra violet light emitting diode (UV-LED) coating layer over the veneer layer for making a surface and bevel of the engineered composite plank water resistant. Further, the engineered composite plank includes an acoustic underlay pre-installed on a bottom surface of the composite core. Furthermore, the engineered composite plank includes a locking system for allowing for fast and reliable installation of the engineered composite plank. 1/1 0 oo 0 TC(

Description

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TC( ENGINEERED COMPOSITE FLOORING AND WALL COVERING PLANKS TECHNICAL FIELD

[0001] The present disclosure is related to the field of flooring and wall covering products. More particularly, the present disclosure relates to an improved engineered composite plank including a composite core made up of stone dust such as, but not limited to, limestone dust.

BACKGROUND

[0002] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

[0003] People like to enhance their living spaces in their homes, offices, and other structures. For example, by adding flooring made of wood, tiles etc. or by covering walls with wooden planks, tiles, or laminate boards. Though many flooring and wall covering options are available in the market, but there is hardly any water resistant flooring solutions that is also economical, easy to install, easy to maintain, and comfortable to walk on.

[0004] For centuries, natural wood such as, oak and other hard woods have been used as materials for flooring and covering walls. The appearance and comfort of flooring made up of natural wood is better than any other flooring or wall covering products that are currently available in the market. The natural wood floors and walls can be a healthy choice for interior environments as it provides a solid smooth surface, without fibres that can trap pollen, particles, dust, animal dander, and allergens that occur with carpets. The natural wood can contribute to healthier indoor air quality when used for flooring or wall covering and may be the best choice for allergy sufferers. The main disadvantage of natural wood flooring or wall covering is that it's expensive. Further, the natural wood flooring or wall covering is difficult to install and may require specialized help. The installation cost is more, which in turn may make the natural wood flooring or wall covering pricier. The natural wood flooring may be affected by fluctuations in humidity and temperature. The cold and damp may cause the natural wood to swell and deform.

[0005] Another existing option for flooring and covering walls include laminate boards that use fibreboard or particle board. The laminate boards are stain resistance, wear resistance, fire resistance, reasonably priced, and are easy to maintain. Sustained exposure to moisture may destabilize the integrity of the fibre board or particle board material in the laminates causing permanent and irreparable damage to the laminate boards. Hence, the natural wood and laminate boards are not good options to be used in areas that are subject to repeated or sustained moisture like in kitchen, bathroom, basement areas, etc.

[0006] Currently, fibreboard is also used to enhance floors and walls. Fibreboard provides good thermal and acoustic improvement and may reduce ridges and uneven surfaces in subfloor. Further, the fibreboard may provide robust and stable support for final floor finish and may help in increasing serviceable life of final floor. Additionally, the fibreboard has high loadbearing and weight resistance. Further the fibreboard is light weight and easy to handle. But fibreboard is weak in comparison to natural wood and is not durable. Further, the fibreboard installation may require more nails and might take more time to install. Though the fibreboard is an inexpensive and eco-friendly material, but it contains chemicals such as urea-formaldehyde, a carcinogen ingredient that can be hazardous if not treated appropriately. Formaldehyde can cause serious lung infection.

[0007] Rubber and vinyl floors are another option that is being used for flooring and wall covering. Rubber and vinyl floors (or walls) are relatively inexpensive option and also have a natural resistance to water and moisture. Rubber and vinyl also suffer from limitations as they are not rigid, so imperfections from the subfloor (or walls) transfers through the rubber or vinyl and may appear on the floor or wall surface which may not look good aesthetically. Further, the strength of adhesives used with rubber and vinyl floors may not do well in moisture that can cause curling damage since the rubber and vinyl floors lack rigidity.

[0008] It is an object of the present invention to overcome or ameliorate the above discussed disadvantages of the prior art, or at least offer a useful alternative. In light of above, there exists a need for water resistant, rigid and economical flooring and wall covering products that are easy to install.

SUMMARY

[0009] To address the above mentioned issues, the present disclosure provides an easy to install water resistant, rigid and economical flooring and wall covering product including an engineered composite plank having a stone dust core for example a limestone dust core, a veneer layer, an acoustic underlay, an ultra violet light emitting diode (UV-LED) coating layer, and a locking system.

[0010] An object of the present disclosure is to provide a durable and water resistant engineered composite plank. The engineered composite plank may be used on a surface such as, but not limited to, on floors, walls, etc. The engineered composite plank can be easily and quickly installed on floors or walls. The engineered composite plank includes a composite core made up of stone dust such as, limestone dust, Poly Vinyl Chloride (PVC), and additives. The engineered composite plank also includes a veneer layer over the composite core and a UV-LED coating layer over the veneer layer. The UV-LED coating layer may improve the surface and bevel of the engineered composite plank water resistant. Further, the UV-LED coating layer may reduce energy consumption and work-piece surface temperature, hence may create a durable protective layer, which ensures a long-lasting finish. The engineered composite plank also includes an acoustic underlay pre-installed on a bottom surface of the composite core is super quiet and flexible designed to reduce the acoustic noise. The engineered composite plank also includes a locking system for allowing for fast and reliable installation of the engineered composite plank. In some embodiments, the locking system comprises a drop lock system comprising a drop lock on one or more ends of the engineered composite plank for allowing for fast and reliable installation of the engineered composite plank.

[0011] An embodiment of the present disclosure provides an engineered composite plank for use in flooring and wall covering. The engineered composite plank includes a composite core comprising stone dust, Poly Vinyl Chloride (PVC), and additives. Further, the engineered composite plank includes a veneer layer adhered on a top surface of the composite core. The engineered composite plank also includes an ultra violet light emitting diode (UV-LED) coating layer over the veneer layer for making a surface and bevel of the engineered composite plank water resistant. Further, the engineered composite plank includes an acoustic underlay pre-installed on a bottom surface of the composite core. Furthermore, the engineered composite plank includes a locking system for allowing for fast and reliable installation of the engineered composite plank.

[0012] In some embodiments, the locking system may comprise a drop lock system having a drop lock on one or more ends of the engineered composite plank for allowing for fast and reliable installation of the engineered composite plank.

[0013] According to an aspect of the present disclosure, the composite core includes 66 percent limestone dust, 22 percent Poly Vinyl Chloride, and 12 percent additives. These percentages of the limestone dust, PVC, and additives in the composite core may vary.

[0014] According to an aspect of the present disclosure, the engineered composite plank has exceptional water resistance. For example, the engineered composite plank may remain resistant to water for many days.

[0015] According to an aspect of the present disclosure, the composite core may limit absorption of water and may not swell, deform, or cup.

[0016] According to another aspect of the present disclosure, the composite core includes a high-density dust polymer core configured to create an extremely high strength and stable base.

[0017] According to another aspect of the present disclosure, the veneer layer is made up of wood.

[0018] According to another aspect of the present disclosure, the veneer layer is a thin timber layer effectively held flat relative to the composite core and therefore may not spoil.

[0019] According to another aspect of the present disclosure, a thickness of the veneer layer is 0.6 millimetre or 1.2 millimetre. The thickness of the veneer layer may vary.

[0020] In some embodiments, the thickness of the veneer layer may be within a range of 0.2 millimetre to 4 millimetre.

[0021] According to another aspect of the present disclosure, the acoustic underlay is a super quiet and flexible layer made up of at least one of a cork, rubber, and IXPE rubber.

[0022] According to another aspect of the present disclosure, the acoustic underlay may provide acoustic and/or thermal insulation. Further, the acoustic underlay may act as a levelling layer for uneven sub floors.

[0023] Another embodiment of the present disclosure provides an engineered composite plank for use on a surface. The engineered composite plank includes a composite core including 66 percent limestone dust, 22 percent Poly Vinyl Chloride, and 12 percent additives. The engineered composite plank also includes a veneer layer adhered on a top surface of the composite core. The veneer layer may be made up of wood. A thickness of the veneer layer may be at least one of 0.6 millimetre and 1.2 millimetre. Further, the engineered composite plank includes an ultra violet light emitting diode (UV-LED) coating layer over the veneer layer for making a surface and bevel of the engineered composite plank water resistant. Furthermore, the engineered composite layer includes an acoustic underlay pre installed on a bottom surface of the composite core. The acoustic underlay is made up of at least one of a cork, rubber, and IXPE (Irradiatedcross-linked polyethylene) rubber. The engineered composite layer also includes a locking system on one or more ends of the engineered composite plank for allowing for fast and reliable installation of the engineered composite plank.

[0024] According to an aspect of the present disclosure, the veneer layer is encapsulated in at least one of vinyl and resin to render the veneer layer wear resistant.

[0025] According to another aspect of the present disclosure, the thickness of the veneer layer may be within a range of 0.2 millimetre to 4 millimetre.

[0026] According to another aspect of the present disclosure, the UV-LED coating layer may include at least one of an 8x layer of primer protectant and a tint.

[0027] Yet another embodiment of the present disclosure provides a composite core for use in flooring and wall covering products. The composite core includes a rigid core made up of a material including stone dust including limestone dust, Poly

Vinyl Chloride (PVC), and additives. The rigid core may include 66% limestone dust, 22 percent PVC, and 12 percent additives.

[0028] According to another aspect of the present disclosure, the additives may include at least one of stabilizers, ACR (Acrylic Ester Copolymer), CPE (Chlorinated Polyethylene), PE (Polyethylene), and Wax.

DETAILED DESCRIPTION

[0029] Preferred features, embodiments and variations of the invention may be discerned from the following detailed description which provides sufficient information for those skilled in the art to perform the invention. The detailed description is not to be regarded as limiting the scope of the preceding summary of the invention in any way.

[0030] Specific embodiments of the present invention are described, by way of example only, with reference to the accompanying drawings, in which:

[0031] Figure 1 illustrates a schematic view 100 of an exemplary engineered composite plank 102, in accordance with an embodiment of the present disclosure.

[0032] The present disclosure provides the engineered composite plank 102 for use in flooring and wall products. A plurality of engineered composite planks may be easily and quickly installed on a floor or a wall.

[0033] Referring to the Figure 1, the schematic view 100 of the exemplary engineered composite plank 102 is shown. The engineered composite plank 102 includes multiple layers of different material. The engineered composite plank 102 has exceptional water resistance. For example, the engineered composite plank may remain resistant to water for many days.

[0034] As shown, the engineered composite plank 102 includes a composite core 104 including stone dust, Poly Vinyl Chloride (PVC), and additives. In an example, the stone dust may include limestone dust. The composite core 104 is a stable, water resistant, and durable base layer of the engineered composite plank 102. The composite core 104 may be a rigid core including limestone dust, PVC, and additives. In a non-limiting example, the composite core 104 includes 66 percent limestone dust, 22 percent Poly Vinyl Chloride (PVC), and 12 percent additives. These percentages of the limestone dust, PVC, and additives in the composite core may vary. Examples of the additives may include, but are not limited to, stabilizers, ACR (Acrylic Ester Copolymer), CPE (Chlorinated Polyethylene), PE (Polyethylene), methyl methacrylate, chlorinated polyethylene, and Wax. The Poly Vinyl Chloride used in the engineered composite plank 102 may or may not be recycled polymer. Additives may effectively control melt fracture, promote plasticization of PVC gel, and improve plasticizing quality of the Poly Vinyl Chloride. In some embodiments, the composite core 104 includes a high-density dust polymer core configured to create an extremely high strength and stable base. Further, the composite core 104 may limit absorption of water and may not swell, deform or cup.

[0035] Further, the engineered composite plank 102 includes a veneer layer 106 adhered on a top surface of the composite core 104. The veneer layer 106 may be a water resistant (or a waterproof layer in some embodiments) glued to the entire top surface of the composite core 104 from edge to edge. The veneer layer 106 may be bonded, or glued with adhesive, to the composite core 104. The veneer layer 106 may be a top surface of the engineered composite plank 102. The veneer layer 106 may be a thin, for example thinner than 1/8 of an inch, adhesive layer of hardwood. In a non-limiting example, a thickness of the veneer layer 106 is 0.6 millimetre. In another non-limiting example, the thickness of the veneer layer 106 is 1.2 millimetre. In some embodiments, the thickness of the veneer layer 106 within a range of 0.2 millimetre to 4 millimetre. The thickness of the veneer layer 106 may vary. The thickness of the veneer layer 106 may be less than 0.2 millimetre or may be more than 4 millimetres.

[0036] Further, the veneer layer 106 may be made up of a suitable material including, but are not limited to, wood, plastic, rubber, decorative plastic, cork, bamboo, tile or stone veneers, decorative vinyl, and linoleum. In some embodiments, the veneer layer 106 may be formed using timber such as, but are not limited to, oak either natural or with stains or coatings, hardwoods including Blackbutt, Spotted Gum, Blue Gum, Jarrah, Tasmanian Oak, Iron Bark, Brush Box, and so forth. In an example, the veneer layer 106 is a printed film made up of Oak.

[0037] In some embodiments, the veneer layer 106 may include a thin timber layer effectively held flat relative to the composite core 104 and therefore may not spoil.

[0038] In some embodiments, the veneer layer 106 is encapsulated in a suitable material such as, but not limited to, vinyl and resin to render the veneer layer 106 wear resistant.

[0039] The engineered composite plank 102 further includes an ultra violet light emitting diode (UV-LED) coating layer 108 over the veneer layer 106 for making a surface and bevel of the engineered composite plank 102 water resistant. In some embodiments, the UV-LED coating layer 108 includes an 8x layer of primer protectant. In alternative embodiments, the UV-LED coating layer 108 may include a tint.

[0040] The UV-LED coating layer 108 may have no smell, therefore, it may not be uncomfortable for people while the floors are being finished or installed with the engineered composite plank 102. The UV-LED coating layer 108 may provide a lasting, durable finish to the engineered composite plank 102. The UV-LED coating layer 108 may make the engineered composite plank 102 resistant to wear and chemical abrasion. Further, the UV-LED coating layer 108 may have a better electrical to optical conversion efficiency, hence there is less or no warm up times, that may result in a combined savings of 90% on electricity for the users. Further, the use of engineered composite plank 102 including the UV-LED coating layer 108 may drastically reduce energy consumption and significantly reduces work-piece surface temperature.

[0041] The engineered composite plank 102 further includes an acoustic underlay 110 pre-installed on a bottom surface of the composite core 104. The acoustic underlay 110 may be glued to the entire bottom surface of the composite core 104 from edge to edge. In some embodiments, the acoustic underlay may be a super quiet and flexible layer made up of a suitable material including such as, but are not limited to, a cork, rubber, and IXPE (irradiated cross-linked polyethylene) rubber. In alternative embodiments, the acoustic underlay 110 may be constructed using recycled cork and rubber. The acoustic underlay 110 may reduce the amount of noise or echo caused by footsteps on the floors (or walls) constructed using the engineered composite plank 102. The acoustic underlay 110 are designed to improve the effect foot impact have on surface flooring constructed using the engineered composite plank 102. Further, the acoustic underlay 110 may reduce the amount of foot noise created by passing traffic.

[0042] Further, the acoustic underlay 110 may offer greater sound insulation and better shock absorbing properties, thus making walking on the floors made using the disclosed engineered composite plank 102 more comfortable. Furthermore, the acoustic underlay 110 may level out minor unevenness in the sub-floor and provide protection against rising dampness. The composite core 104 is an extremely strong, stable and moisture-proof core made up of limestone dust, PVC and additives. The acoustic underlay 110 may also prevent the composite core 104 from warping or collapsing.

[0043] Further, the acoustic underlay 110 provides acoustic and/or thermal insulation. Additionally, the acoustic underlay 110 may act as a levelling layer for uneven sub floors.

[0044] In some embodiments, a thickness of the acoustic underlay 110 may be in a range of 2 mm to 4 mm. In alternative embodiments, the thickness of the acoustic underlay 110 may be less than 2mm or more than 4mm. Further, the acoustic underlay 110 may be formed using sponge rubber, foam, etc. In some embodiments, the acoustic underlay 110 may include ultra-dense polyolefin acoustic foam that may substantially reduce noise caused by foot traffic.

[0045] Furthermore, the engineered composite plank 102 includes a locking system 112 for allowing for fast and reliable installation of the engineered composite plank 102. In some embodiments, the locking system 102 may include 5G@ locking system for fast and easy installation of a plurality of engineered composite plank 102 on a surface. The 5G@locking system may include a flexible plastic tongue and a wedge groove. The plurality of engineered composite plank 102 including the 5G@ locking system may be locked on a long side with a traditional angling method. Further, on a short side, the different types of the 5G@locking system may enable simple and fast installation by vertical snap or side push without the need of any tools. For example, when the engineered composite plank 102 is folded down, the flexible plastic tongue may be pushed into a tongue-groove. As the engineered composite plank 102 reaches its final position, the flexible plastic tongue snaps out into the wedge groove, and may emit a click sound for locking the engineered composite plank 102 vertically.

[0046] In alternative embodiments, the locking system 112 comprises a drop lock system comprising a drop lock on one or more ends of the engineered composite plank

102 for allowing for fast and reliable installation of the engineered composite plank 102. In other embodiments, the locking system 112 may be a clip lock interlocking-based locking system. The locking system 112 may enable two or more engineered composite planks 102 to clip together while installation on a surface and stay together on the surface after installation. An angle, size, and dimensions of the locking system 112 may vary depending on the size, and shape of the engineered composite plank 102. The locking system 112 may resist external forces and may prevent engineered composite plank 102 from separating or sliding against one another when installed on a surface like floor, wall, and so forth. The locking system 112 may work in tandem with the precision of the design of the engineered composite plank 102 to help conceal any subfloor or surface imperfections.

[0047] Though a shape of the engineered composite plank 102 is shown as a rectangle but a person skilled in art will understand that a shape and size of engineered composite plank 102 may vary depending on the surface i.e. the floor and/or wall where the engineered composite plank 102 need to be installed.

[0048] The disclosed engineered composite plank 102 is water resistant, stable and durable. Further, the disclosed engineered composite plank 102 is easy and fast to install.

[0049] Further, the composite core 104 including the limestone dust makes the engineered composite plank 102 stable, and highly durable.

[0050] The veneer layer 106 makes the engineered composite plank 102 aesthetically appealing and may give a realistic feel of timber plank. Further, the engineered composite plank 102 may be manufactured in every possible shade and in various plank dimensions as per the requirement. The veneer layer 106 makes the makes the engineered composite plank 102 strong and durable. The engineered composite plank 102 having the veneer layer 106 is designed to withstand seasonal humidity changes in indoor and outdoor areas.

[0051] The UV-LED coating layer 108 on the engineered composite plank 102 may make the engineered composite plank 102 ultra-durable. Further, the UV-LED coating layer 108 may make a surface and bevel of the engineered composite plank 102 water-resistant. The acoustic underlay 110 may make the engineered composite plank 102 super quiet to walk on when installed on floors.

[0052] In some embodiments, the locking system 112 with drop lock on the ends of the engineered composite plank 102 may allow for fast and reliable installation.

[0053] The locking system 112 with the 5G@ locking system may enable fast and easy installation of a plurality of engineered composite plank 102 on a surface.

[0054] The disclosed engineered composite plank 102 is highly resistant to impact. In some embodiments, the disclosed engineered composite plank 102 may be fire resistant.

[0055] The disclosed engineered composite plank 102 is scratch, and chemical resistant. The engineered composite plank 102 is exceedingly sturdy and ultra durable. The engineered composite plank 102 is strong enough to last for many years. The disclosed engineered composite plank 102 may be a cost-effective solution for flooring and wall covering.

[0056] Further, the engineered composite plank 102 may be easy and quick to install on floors and walls. The floors and walls made by using the disclosed engineered composite plank 102 may be easy to maintain.

[0057] As the disclosed engineered composite plank 102 is water resistant, sturdy, scratch and chemical resistant, therefore may be used in kitchen, outdoors, bathrooms, and so forth. Further, the engineered composite plank 102 having the UV-LED coating layer 108 may have an anti-static surface to prevent dust and dirt from collecting between multiple engineered composite plank 102 installed into a surface such as, but not limiting to, a floor or wall.

[0058] According to an aspect of the present disclosure, the disclosed engineered composite plank 102 has exceptional water resistance. For example, the engineered composite plank 102 may remain resistant to water for many days.

[0059] According to an aspect of the present disclosure, the composite core 104 may limit absorption of water and may not swell or cup.

[0060] According to another aspect of the present disclosure, the composite core 104 includes a high-density dust polymer core configured to create an extremely high strength and stable base.

[0061] According to another aspect of the present disclosure, the veneer layer 106 is a thin timber layer effectively held flat relative to the composite core 104 and therefore may not spoil.

[0062] According to another aspect of the present disclosure, the acoustic underlay 110 may provide acoustic and/or thermal insulation. Further, the acoustic underlay 110 may act as a levelling layer for uneven sub floors.

[0063] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of' is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

[0064] Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

[0065] Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1. An engineered composite plank for use in flooring and wall covering, comprising:

a composite core comprising stone dust, Poly Vinyl Chloride (PVC), and additives;

a veneer layer adhered on a top surface of the composite core;

an ultra violet light emitting diode (UV-LED) coating layer over the veneer layer for making a surface and bevel of the engineered composite plank water resistant;

an acoustic underlay pre-installed on a bottom surface of the composite core; and

a locking system on one or more ends of the engineered composite plank for allowing for fast and reliable installation of the engineered composite plank.

2. The engineered composite plank of claim 1, wherein the composite core comprises 66 percent limestone dust, 22 percent Poly Vinyl Chloride, and 12 percent additives.

3. The engineered composite plank of claim 1, wherein the composite core comprises a high-density dust polymer core configured to create an extremely high strength and stable base.

4. The engineered composite plank of claim 1, wherein the composite core is configured to limit absorption of water and not to swell, deform, or cup.

5. The engineered composite plank of claim 1, wherein the veneer layer is made up of wood.

6. The engineered composite plank of claim 1, wherein the UV-LED coating layer comprises at least one of an 8x layer of primer protectant and a tint.

7. The engineered composite plank of claim 1, wherein a thickness of the veneer layer is at least one of 0.6 millimetre or 1.2 millimetre.

8. The engineered composite plank of claim 1, wherein a thickness of the veneer layer is within a range of 0.2 millimetre to 4 millimetre.

9. The engineered composite plank of claim 1, wherein the veneer layer comprises a thin timber layer effectively held flat relative to the composite core.

10. The engineered composite plank of claim 1, wherein the acoustic underlay is a super quiet and flexible layer made up of at least one of a cork, rubber, and IXPE (Irradiated cross-linked polyethylene) rubber.

11.The engineered composite plank of claim 10, wherein the acoustic underlay provides acoustic and/or thermal insulation, further wherein the acoustic underlay acts as a levelling layer for uneven sub floors.

12.The engineering composite plank of claim 1, wherein the veneer layer is encapsulated in at least one of vinyl and resin to render the veneer layer wear resistant.

13.The engineered composite plank of claim 1, wherein the additives comprising at least one of stabilizers, ACR (Acrylic Ester Copolymer), CPE (Chlorinated Polyethylene), PE (Polyethylene), and Wax.

14.An engineered composite plank for use on a surface, comprising:

a composite core comprising 66 percent limestone dust, 22 percent Poly Vinyl Chloride, and 12 percent additives, the composite core is configured to limit absorption of water and not to swell, deform or cup;

a veneer layer adhered on a top surface of the composite core, wherein the veneer layer is made up of wood, wherein a thickness of the veneer layer is at least one of 0.6 millimetre or 1.2 millimetre;

an acoustic underlay pre-installed on a bottom surface of the composite core, wherein the acoustic underlay is made up of at least one of a cork, rubber, and IXPE (Irradiated cross-linked polyethylene) rubber, wherein the acoustic underlay provides acoustic and/or thermal insulation, further wherein the acoustic underlay acts as a levelling layer for uneven sub floors; and

15.The engineering composite plank of claim 14, wherein the veneer layer is encapsulated in at least one of vinyl and resin to render the veneer layer wear resistant.

16.The engineered composite plank of claim 14, wherein the thickness of the veneer layer is within a range of 0.2 millimetre to 4 millimetre.

17.The engineered composite plank of claim 14, wherein the UV-LED coating layer comprises at least one of an 8x layer of primer protectant and a tint.

18.The engineered composite plank of claim 14, wherein the additives comprising at least one of stabilizers, ACR (Acrylic Ester Copolymer), CPE (Chlorinated Polyethylene), PE (Polyethylene), and Wax.

19.The engineered composite plank of claim 14, wherein the composite core comprises a high-density dust polymer core configured to create an extremely high strength and stable base.

20.A composite core for use in flooring and wall covering products, comprising:

a rigid core made up of a material comprising stone dust comprising limestone dust, Poly Vinyl Chloride (PVC), and additives, wherein the rigid core comprises 66% of limestone dust, 22 percent PVC, and 12 percent additives.

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FIG. 1