EP3317094A1 - Revêtements de surface stratifiés - Google Patents

Revêtements de surface stratifiés

Info

Publication number
EP3317094A1
EP3317094A1 EP16818951.2A EP16818951A EP3317094A1 EP 3317094 A1 EP3317094 A1 EP 3317094A1 EP 16818951 A EP16818951 A EP 16818951A EP 3317094 A1 EP3317094 A1 EP 3317094A1
Authority
EP
European Patent Office
Prior art keywords
floor panel
edge
dimensional stability
length
width
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16818951.2A
Other languages
German (de)
English (en)
Other versions
EP3317094A4 (fr
Inventor
John R. Eshbach
Brent L. Stoll
Kean M. Anspach
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AFI Licensing LLC
Original Assignee
AFI Licensing LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AFI Licensing LLC filed Critical AFI Licensing LLC
Publication of EP3317094A1 publication Critical patent/EP3317094A1/fr
Publication of EP3317094A4 publication Critical patent/EP3317094A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/22—Layered products comprising a layer of synthetic resin characterised by the use of special additives using plasticisers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions 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
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    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
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    • B32B2309/08—Dimensions, e.g. volume
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    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
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Definitions

  • the present invention generally relates to laminated vinyl flooring panels which demonstrate unexpected dimensional stability.
  • Vinyl based flooring products having plasticized vinyl wear layers have generally been manufactured using discontinuous stack press processes or continuous processes in which the planks are cut in the machine direction. Discontinuous processes are inefficient and continuous processes wherein planks are cut in the machine direction can result in products that do not have adequate dimensional stability; or require heat relaxation (annealing) prior to final cutting in order to provide adequate dimensional stability.
  • dimensional stability can be measured in a variety of ways
  • the dimensional stability of vinyl based flooring products is sometimes measured by the extent to which a dimension shrinks relative to the entire length of that particular dimension.
  • Dimensional stability issues often present as gaps between adjacent planks in a flooring system. These gaps are particularly pronounced when they occur in the length direction, because shrinkage along the length is visible in a single gap; and because the length is longer than the width, a single gap can become quite large over time.
  • the present invention provides a floor panel comprising: a plurality of vinyl layers; a first edge, a second edge opposite the first edge, a third edge, and a fourth edge opposite the third edge; a length measured from the first edge to the second edge; a width measured from the third edge to the fourth edge, the length being greater than the width; a first dimensional stability in the length direction of the floor panel; and a second dimensional stability in the width direction of the floor panel, the first dimensional stability being greater than the second dimensional stability.
  • the present invention provides a flooring system comprising: a plurality of floor panels, each of the plurality of floor panels comprising: a plurality of vinyl layers; a first edge, a second edge opposite the first edge, a third edge, and a fourth edge opposite the third edge; a length measured from the first edge to the second edge; a width measured from the third edge to the fourth edge, the length being greater than the width; a first dimensional stability in the length direction of the floor panel; and a second dimensional stability in the width direction of the floor panel, the first dimensional stability being greater than the second dimensional stability; and wherein the plurality of floor panels are arranged in a pattern such that the length direction of the plurality of floor panels extend substantially parallel to one another.
  • Still further embodiments provide a method of forming a multi-layer floor panel comprising: a) providing a top base vinyl layer and a bottom base vinyl layer; b) feeding the top base vinyl layer and the bottom base vinyl layer into a roller assembly in a machine direction; c) laminating said top base layer and said bottom base layer together with the roller assembly to form a layered composite sheet, the layered composite sheet exiting the roller assembly in the machine direction; and d) cutting the layered composite sheet in an across -machine direction to form a floor panel, the floor panel having a length in the across-machine direction and a width in the machine direction, the length being greater than the width.
  • FIG. 1 depicts a side elevation schematic diagram of an exemplary laminating system used to perform exemplary methods of the present invention.
  • FIG. 2 is a top plan view of exemplary multi-layer floor panels of the present invention showing the fabrication process material flow (machine direction) and across machine direction.
  • any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention.
  • Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation.
  • the present invention provides a floor panel comprising: a plurality of vinyl layers; a first edge, a second edge opposite the first edge, a third edge, and a fourth edge opposite the third edge; a length measured from the first edge to the second edge; a width measured from the third edge to the fourth edge, the length being greater than the width; a first dimensional stability in the length direction of the floor panel; and a second dimensional stability in the width direction of the floor panel, the first dimensional stability being greater than the second dimensional stability.
  • the ratio of the length to the width is from about 25: 1 to about 1.25: 1. In some embodiments, the ratio of the length to the width is from about 20: 1 to about 1.5: 1. In some embodiments, the ratio of the length to the width is from about 15: 1 to about 2: 1. In some embodiments, the ratio of the length to the width is from about 10: 1 to about 3: 1. In some embodiments, the ratio of the length to the width is from about 8: 1 to about 4: 1. In some embodiments, the ratio of the length to the width is from about 7: 1 to about 5: 1. In some embodiments, the ratio of the length to the width is about 6: 1. In some embodiments, the present invention provides a floor panel wherein a ratio of the length to the width is greater than or equal to 1.5: 1.
  • the width of said floor panel is from about 7.5 cm to about 35 cm. In some embodiments, the width of said floor panel is from about 10 cm to about 30 cm. In some embodiments, the width of said floor panel is from about 12.5 cm to about 25 cm. In some embodiments, the width of said floor panel is from about 15 cm to about 22.5 cm. In some embodiments, the width of said floor panel is about 15 cm.
  • the length of said floor panel is from about 75 cm to about 325 cm. In some embodiments, the length of said floor panel is from about 80 cm to about 300 cm. In some embodiments, the length of said floor panel is from about 85 cm to about 250 cm. In some embodiments, the length of said floor panel is from about 90 cm to about 200 cm. In some embodiments, the length of said floor panel is from about 100 cm to about 150 cm. In some embodiments, the length of said floor panel is from about 105 cm to about 125 cm. In some embodiments, the length of said floor panel is about 90 cm. In some embodiments, the length of said floor panel is about 122 cm. In some embodiments, the length of said floor panel is about 152 cm. In some embodiments, the length of said floor panel is about 182 cm.
  • the thickness of said floor panel is from about 0.2 cm to about 1 cm. In some embodiments, the thickness of said floor panel is from about 0.3 cm to about 0.9 cm. In some embodiments, the thickness of said floor panel is from about 0.4 cm to about 0.8 cm. In some embodiments, the thickness of said floor panel is about 0.3 cm.
  • the plurality of vinyl layers are laminated together to form a layered composite.
  • the layered composite comprises a core comprising a top base vinyl layer and a bottom base vinyl layer.
  • Each of the top base vinyl layer and the bottom base vinyl layer may comprise binder and plasticizer.
  • binder include vinyl polymer - such as polyvinyl chloride (PVC).
  • the plasticizer may be a phthalate plasticizer, a non-phthalate plasticizer, or a combination thereof.
  • each of the top base vinyl layer and the bottom base vinyl layer may further comprise filler.
  • the filler may comprise limestone (calcium carbonate).
  • the top base vinyl layer and the bottom base vinyl layer have substantially similar compositions. In other embodiments, the top base vinyl layer and the bottom base vinyl layer have different compositions.
  • the top base vinyl layer may comprise about 20 wt. % to about 40 wt. % of binder based on the total weight of the top base vinyl layer - including all integers and sub-ranges there between.
  • the bottom base vinyl layer may comprise about 20 wt. % to about 40 wt. % of binder based on the total weight of the bottom base vinyl layer - including all integers and sub-ranges there between.
  • the top base vinyl layer has a thickness of about 30 mils to 50 mils.
  • the top base vinyl layer has thickness of about 40 mils. In some embodiments, the bottom base vinyl layer has a thickness of about 50 mils to 70 mils. In one non-limiting example, the bottom base vinyl layer has thickness of about 60 mils.
  • the top base vinyl layer and bottom base vinyl layer are laminated together without any intervening layers.
  • the core comprises a scrim layer.
  • the scrim may be non-woven scrim.
  • the core may be a glass scrim.
  • the scrim may have a thickness ranging from about 1 mil to 5 mils. In some embodiments, the scrim has a thickness of about 2 mils.
  • the scrim layer may be sandwiched between the top base vinyl layer and bottom base vinyl layer. Still further embodiments provide a plastisol saturated glass scrim layer sandwiched between the top base vinyl layer and bottom base vinyl layer.
  • the plastisol may comprise a suspension of polyvinyl chloride (PVC) particles in plasticizer.
  • PVC polyvinyl chloride
  • the plurality of layers further comprises a rigid vinyl wear layer that forms an uppermost surface of the floor panel.
  • the rigid vinyl wear layer may have a thickness ranging from about 5 to about 35 mils - including all integers and sub-ranges there between.
  • the rigid vinyl wear layer has a thickness ranging from about 10 to about 30 mils.
  • the rigid vinyl wear layer has a thickness of about 20 mils.
  • the rigid vinyl wear layer is applied to a top surface of the core.
  • the plurality of layers further comprises a decorative layer that may comprise an ink layer.
  • the decorative layer may comprise an ink layer and a rigid or semi-rigid vinyl print film having a thickness ranging from about 2 mils to about 5 mils - including all integers and sub-ranges there between.
  • the rigid or semi-rigid vinyl print film has a thickness of about 3 mils.
  • the decorative layer is positioned between the rigid vinyl wear layer vinyl wear and the core, wherein the ink layer is adjacent to the rigid vinyl wear layer and the decorative layer is adjacent to the core.
  • the plurality of layers are laminated together to form the layered composite in a continuous process having a machine direction and an across -machine direction; wherein the width extends in the machine direction and the length extends in the across-machine direction.
  • the layered composite comprises a top surface and a bottom surface, the top surface or the bottom surface comprising colored striations extending in the width direction.
  • Still further embodiments provide a floor panel wherein the first edge comprises a first mechanical locking profile, the second edge comprises a second mechanical locking profile, the third edge comprises a third mechanical locking profile, and the fourth edge comprises a fourth mechanical locking profile; wherein the first and second mechanical locking profiles are configured to provide horizontal and vertical locking when coupled together; and wherein the third and fourth mechanical locking profiles are configured to provide horizontal and vertical locking when coupled together.
  • the first dimensional stability is at least two times greater than the second dimensional stability.
  • dimensional stability is evaluated by resistance to shrinkage.
  • shrinkage means the extent to which a dimension contracts relative to the entire span of that particular dimension, which may be considered a rate of shrinkage in certain embodiments.
  • the present inventors have discovered that the processes used to manufacture vinyl based surface coverings result in products having different stress-strain characteristics in the machine direction and across machine direction.
  • the sheet is pressed between rollers which results in elongation (and thinning) of the laminate sheet in the machine direction, with minimal elongation in the across machine direction.
  • the stress/strain characteristics of the sheet are permanently altered in the machine direction. While these differences may go unnoticed in certain installations or under certain conditions, they are critical in flooring systems which are exposed to varying environmental conditions.
  • the first dimensional stability is a first resistance to shrinkage of the floor panel in the length direction and the second dimensional stability is a second resistance to shrinkage of the floor panel in the width direction.
  • Some embodiments provide a flooring system comprising: a plurality of floor panels, each of the plurality of floor panels comprising: a plurality of vinyl layers; a first edge, a second edge opposite the first edge, a third edge, and a fourth edge opposite the third edge; a length measured from the first edge to the second edge; a width measured from the third edge to the fourth edge, the length being greater than the width; a first dimensional stability in the length direction of the floor panel; and a second dimensional stability in the width direction of the floor panel, the first dimensional stability being greater than the second dimensional stability; and wherein the plurality of floor panels are arranged in a pattern such that the length direction of the plurality of floor panels extend substantially parallel to one another.
  • each of the plurality of floor panels further comprises: a first edge comprising a first mechanical locking profile; a second edge comprising a second mechanical locking profile; a third edge comprising a third mechanical locking profile; and a fourth edge comprising a fourth mechanical locking profile; wherein the plurality of floor panels are arranged in the pattern such that the first and second mechanical locking profiles of longitudinally adjacent ones of the plurality of floor panels mechanically mate with one another to provide horizontal and vertical locking; and wherein the plurality of floor panels are arranged in the pattern such that the third and fourth mechanical locking profiles of transversely adjacent ones of the plurality of floor panels mechanically mate with one another to provide horizontal and vertical locking.
  • Still further embodiments provide a flooring system wherein for each of the plurality of floor panels, the first dimensional stability is a first resistance to shrinkage of the floor panel in the length direction and the second dimensional stability is a second resistance to shrinkage of the floor panel in the width direction.
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A perspective view of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of exemplary embodiment of exemplary embodiment of a multi-layer floor panel
  • FIG. 1 A block diagram illustrating an exemplary embodiment of exemplary embodiment of exemplary embodiment of exemplary embodiment of a multi
  • the floor panel has a first dimensional stability in the length direction of the floor panel and a second dimensional stability in the width direction of the floor panel, wherein the first dimensional stability is greater than the second dimensional stability.
  • the first dimensional stability is a first resistance to shrinkage of the floor panel in the length direction and the second dimensional stability is a second resistance to shrinkage of the floor panel in the width direction.
  • steps a) to d) are performed as part of a continuous process.
  • the top base vinyl layer has a first thickness in step a) and the bottom base vinyl layer has a second thickness in step a), wherein the top base vinyl layer has a third thickness subsequent to step c) and the bottom base vinyl layer has a fourth thickness subsequent to step c), and wherein the first thickness is greater than the third thickness and the second thickness is greater than the fourth thickness.
  • step d) comprises repetitively cutting the layered composite sheet, with a cutting apparatus, in the across-machine direction to form a plurality of the floor panels, wherein the layered composite sheet is continuously fed into the cutting apparatus.
  • the layered composite sheet comprises a width measured in the across-machine direction upon exiting the roller assembly, and wherein the length of the floor panel is substantially the same as the width of the layered composite sheet.
  • an annealing step is not performed prior to step d). In further embodiments, an annealing step is not required at all.
  • laminating system 100 comprises a conveyor type laminating system comprising a roller assembly.
  • the roller assembly comprises a plurality of belts 160a, 160b, 160c, 160d; and a plurality of belt rollers 111, 112, 113, 121, 122, 123, 131, 132, 133.
  • belt rollers 122, 123, 132, 133 provide a laminating function.
  • laminating system 100 further comprises first hopper 110, second hopper 120 and third hopper 130. [00041] In some embodiments, first hopper 110 contains a first granulate 114.
  • first granulate 114 comprises the components which form the bottom base vinyl layer 115.
  • first hopper 110 feeds first granulate 114 to belt rollers 111, 112, 113 which deliver first granulate 114 to conveyor belt 160a.
  • belt rollers 111, 112, 113 are heated to such temperature that first granulate 114 melts to an extent sufficient to weaken it to a mass which can be shaped into a solid continuous sheet, e.g. bottom base vinyl layer 115. As one skilled in the art will appreciate, the heating temperature will depend on the components used in first granulate 114.
  • bottom base vinyl layer 115 comprises a vinyl chloride polymer (e.g. a PVC homopolymer) and filler.
  • bottom base vinyl layer 115 further comprises a plasticizer.
  • bottom base vinyl layer 115 further comprises a stabilizer.
  • the stabilizer is a PVC stabilizer.
  • second hopper 120 contains a second granulate 124.
  • second granulate 124 comprises the components which form the top base vinyl layer 125.
  • second hopper 120 feeds second granulate 124 to belt rollers 121, 122, 123.
  • belt rollers 121, 122, 123 are heated to such temperature that second granulate 124 melts to an extent sufficient to weaken it to a mass which can be shaped into a solid continuous sheet, e.g. top base vinyl layer 125.
  • belt rollers 122, 123 laminate top base vinyl layer to the top surface of bottom base vinyl layer to form a laminated composite.
  • the laminated composite comprising top base vinyl layer and bottom base vinyl layer is fed to conveyor belt 160c.
  • the heating temperature will depend on the components used in second granulate 124.
  • top base vinyl layer 125 comprises a vinyl chloride polymer (e.g. a PVC homopolymer) and filler.
  • top base vinyl layer 125 further comprises a plasticizer.
  • top base vinyl layer 125 further comprises a stabilizer.
  • the stabilizer is a PVC stabilizer.
  • the terms “fabric” and “scrim” are used interchangeably, and refer to a generally planar textile structure of yarns, filaments and fibers having a facing and a lower surface.
  • the fabric or scrim is woven or non- woven.
  • woven refers to a fabric or scrim formed by weaving two sets of yarns.
  • non-woven refers to an assembly of fibers held together by interlocking the fibers in a mat, by fusing of the fibers, or by bonding the fibers with an adhesive.
  • the multi-layer floor panel comprises a scrim. In some embodiments, the multi-layer floor panel comprises a glass scrim. In some embodiments, the glass scrim is saturated with plastisol.
  • laminating system 100 further comprises glass roller 140 which provides a glass scrim for the multi-layer floor panel.
  • a sheet of woven or non-woven fabric is spooled around glass roller 140.
  • glass roller 140 delivers the non-woven or woven fabric 145 to glass laminator 141, 142, which laminates the lower surface of the non- woven or woven fabric 145 to the top surface of the bottom base vinyl layer 115.
  • top base vinyl layer 125 is applied to the facing of the non- woven or woven fabric 145.
  • third hopper 130 contains a third granulate 134.
  • third granulate 134 comprises the components which form a wear layer 135.
  • wear layer 135 is laminated to the top surface of the laminated composite comprising bottom base vinyl layer 115 and top base vinyl layer 125 to form a multi-layer flooring sheet 190.
  • the multi-layer flooring sheet 190 is delivered by belt rollers 132, 133 to conveyor belt 160d.
  • a UV curable coating is applied to the wear layer 135.
  • laminating system 100 further comprises cutting apparatus 150.
  • cutting apparatus 150 comprises a die cutter.
  • laminating system 100 further comprises cutting apparatus 150, the multi-layer floor panel is cut across machine direction (AMD), into planks 200 of desired dimension.
  • AMD machine direction
  • a multi-layer continuous sheet is cut in the across machine direction to provide planks 200, having a length L in the across machine direction (AMD) that is greater than a width W in the machine direction (MD).
  • AMD across machine direction
  • MD machine direction
  • the resulting floor panels may exhibit anisotropic dimensional stability. Specifically, the floor panel will exhibit greater dimensional stability (less shrinkage per unit length) along the AMD as compared to the MD.
  • the anisotropic dimensional stability results from the directional stress/strain applied along the MD by the rollers to the polymeric composition during processing of the floor panel.
  • the MD stress that is applied to the polymeric composition causes the resulting floor panel to later shrink along the MD over time due when exposed to certain conditions (e.g. heat, light, wear, etc.).
  • certain conditions e.g. heat, light, wear, etc.
  • laminating system 100 further comprises a radiation source 170.
  • radiation source 170 comprises ultraviolet radiation or infrared radiation.
  • radiation source 170 comprises a plurality of infrared heaters.
  • radiation source 170 comprises a plurality of infrared heaters, which are positioned at a desired height above the top surface of belts 160a, 160b, 160c, 160d.
  • radiation source 170 comprises a plurality of infrared heaters, which are positioned strategically along laminating system 100, for example above conveyor belts 160a and 160b.
  • the radiation source comprises a plurality of IR heaters (otherwise referred to as a plurality of heat lamps) that operate at a temperature ranging from about 150 °F to about 180 °F.
  • radiation source 170 provides heat sufficient to ensure that the laminated sheet has the appropriate consistency and texture.
  • the composite sheet comprising the bottom base vinyl layer 115 and the top base vinyl layer 125 and optionally scrim 145, is subjected to a drum process similar to the processes described in U.S. Patent Application Serial No. 14/108,019.
  • the drum process employs a process drum having a diameter, and one or more laminating stations associated with the drum.
  • the laminating stations may include a printing station, an embossing station, and a coating station disposed at different circumferential locations spaced around the drum.
  • each sample was prepared by rolling at least one vinyl layer between rollers along a machine direction, thereby creating an elongated sheet of vinyl material spanning the machine direction.
  • the elongated sheet of vinyl material was then heated with IR heaters at a temperature between 150 °F and 180 °F.
  • the sheet of vinyl material was then cut to a plurality of panels having a predetermined length and width and left for 24 hours at room temperature. Specifically, each panel was cut so that the length of the panel followed the AMD and the width of the panel followed the MD.
  • each panel was then tested for dimensional stability according to the ASTM D1204 (measurement of dimensional stability of linear dimensional change resulting from exposure to elevated temperature). Specifically, the initial dimensions of each panel was measured using a block and dial gauge. The initial dimensions were recorded as the initial length and initial width of each panel.
  • the plurality of panels was cut into two batches, with the first batch (i.e., Example 1) including 23 individual panels having a predetermined length and a predetermined width.
  • the second batch i.e. Example 2 included 24 individual panels having a predetermined length of 18 inches and a predetermined width of 18 inches.
  • each batch was then placed in an oven operating at a temperature of 150 °F for 30 minutes, after which the batches were removed from the oven and allowed to cool to room temperature. Once at room temperature, the final dimensions of each sample were re-measured using a block and dial gauge. The final dimensions were recorded as the final length and final width of each sample panel.
  • the dimensional retention along the AMD is greater than along the MD. Furthermore, the dimensional change per foot is much greater along the MD as compared to the AMD. Therefore, for floor panels having a length to width ratio ranging from 25: 1 to 1.25: 1, there will be a greater reduction in overall floor panel shrinkage by cutting floor panels so that the length follows the AMD (as compared to cutting the length along the MD). Although the MD will still exhibit a greater dimension change per unit along the MD (as compared to the AMD), the width of the flooring panel is smaller overall as compared to the length of the flooring panel.
  • the overall amount of shrinkage in the flooring panel will be reduced (thereby enhancing dimensional stability) because along the width cannot be greater than the amount of shrinkage wherein resulting floor panels that have much greater overall dimensional stability and shrink less over time.
  • along the AMD direction there is less dimensional change per unit length as compared to that of the MD.
  • the longer dimension (i.e. length) of the floor panel along the AMD because having less change per unit length along longer distances will result in an overall reduction in the amount of reduced amount of change in dimension per unit length along greater distance have exhibit an overall much greater dimensional stability

Abstract

L'invention concerne des panneaux de plancher, lesquels panneaux comprennent : une pluralité de couches de vinyle ; un premier bord, un deuxième bord opposé au premier bord, un troisième bord, et un quatrième bord opposé au troisième bord ; une longueur mesurée à partir du premier bord jusqu'au deuxième bord ; une largeur mesurée à partir du troisième bord jusqu'au quatrième bord, la longueur étant supérieure à la largeur ; une première stabilité dimensionnelle dans la direction de la longueur du panneau de plancher ; et une seconde stabilité dimensionnelle dans le sens de la largeur du panneau de plancher, la première stabilité dimensionnelle étant supérieure à la seconde stabilité dimensionnelle. L'invention concerne également des procédés de réalisation et des systèmes utilisant ces panneaux.
EP16818951.2A 2015-07-02 2016-07-05 Revêtements de surface stratifiés Withdrawn EP3317094A4 (fr)

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US201562187925P 2015-07-02 2015-07-02
PCT/US2016/040942 WO2017004614A1 (fr) 2015-07-02 2016-07-05 Revêtements de surface stratifiés

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NL2018440B1 (en) 2017-02-28 2018-09-19 Champion Link Int Corp Panel suitable for assembling a waterproof floor or wall covering, method of producing a panel
CN110103437A (zh) * 2018-01-05 2019-08-09 无锡市博宇塑机有限公司 塑胶地板层状强化结构及其制造设备与成型方法

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US3983307A (en) * 1975-09-29 1976-09-28 Formica Corporation Thin, tough, stable laminate
JPS59220555A (ja) * 1983-05-30 1984-12-12 東洋リノリユ−ム株式会社 ビニル床タイル
SE526728C2 (sv) * 2003-12-11 2005-11-01 Pergo Europ Ab Ett förfarande för framställning av paneler med en dekorativ yta
DE102006024305B3 (de) * 2006-05-24 2007-10-25 Flooring Technologies Ltd. Paneel und Verfahren zur Herstellung eines Paneels
EP1925461B1 (fr) * 2006-10-05 2013-11-06 Spanolux N.V. Div. Balterio Procédé de fabrication d'un panneau de grande surface, et panneau de grande surface
BE1018177A3 (nl) * 2008-06-10 2010-06-01 Flooring Ind Ltd Sarl Bedrukt substraat, werkwijze voor het vervaardigen van vloerpanelen en werkwijze voor het vervaardigen van bedrukte substraten.
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AU2021201438A1 (en) 2021-03-25
CN107708987A (zh) 2018-02-16
TW201708673A (zh) 2017-03-01
AU2016287834A1 (en) 2017-12-21
WO2017004614A1 (fr) 2017-01-05

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