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
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer 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 shape; Layered products comprising a layer 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 shape; Layered products comprising a layer 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
• • 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
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
• • 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
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B21/042—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood 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
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/12—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board next to a particulate 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
• • 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
  • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
• • B—PERFORMING OPERATIONS; TRANSPORTING
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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
  • B32B7/03—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 with respect to the orientation of features
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
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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
  • E04F15/102—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 fibrous or chipped materials, e.g. bonded with synthetic resins
• • 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
  • B32B2250/00—Layers arrangement
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2250/00—Layers arrangement
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2250/00—Layers arrangement
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2250/00—Layers arrangement
  • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• • B—PERFORMING OPERATIONS; TRANSPORTING
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2255/00—Coating on the layer surface
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• • 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
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/402—Coloured
  • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
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  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
  • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B32B2471/00—Floor coverings
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
  • E04F2201/0107—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
  • E04F2201/0115—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges with snap action of the edge connectors

Definitions

• the present disclosure relates to flooring planks and methods of making same.
• it relates to flooring planks comprising a core that comprises calcium carbonate.
• wood is an organic hygroscopic compound which needs to be protected from heat, humidity and water.
• wood and wood-based materials are susceptible to both structural and cosmetic damage from heat, water, fungal decay and mold.
• wood For its various uses, wood must be protected from attack by insects, fungi and other organisms. Insects, such as termites, beetles and carpenter ants may cause extensive and costly damage to wood structures. If left unprotected or unpreserved, the wood will decay and deteriorate within a period of a few months to a few years, depending upon climate and soil conditions.
• one concern with commercially available flooring plank is the water and moisture resistance of the finished product and the sensitivity of the raw wood material to heat, water and moisture after the installation process.
• edge peaking of the flooring plank due to swelling and such edge peaking can result in edge chip-off or premature wear- out of the plank.
• the susceptibility to moisture content discourages people from installing wood flooring planks in areas which are subject to having water on the surface of the floor, such as in the kitchen and bathroom areas.
• the present disclosure relates to a flooring plank including a core comprising a core comprising at least 50 wt. % of calcium carbonate by weight; a first wood veneer having a first grain direction and being affixed to one surface of the core; and a second wood veneer having a second grain direction and being affixed on top of the first wood veneer.
• the present disclosure relates to a flooring plank comprising a core comprising at least 50 wt. % of calcium carbonate by weight; and at least one wood veneer affixed on one surface of the core, said at least one one veneer comprising about 55 to about 90 % of a veneer resin by weight based on the total weight of the veneer.
• the present disclosure relates to a flooring plank comprising a core comprising at least 50 wt. % of calcium carbonate by weight; at least one wood veneer affixed on one surface of the core; and a veneer resin, said plank comprising about 55 to about 90 % of a veneer resin by weight based on the total weight of the plank.
• the present disclosure relates to a flooring plank comprising a core comprising at least 50 wt. % of calcium carbonate by weight based on the total weight of the core and at least 10 wt. % of a core resin by weight based on the total weight of the core, said core having a density of at least 1000 kg/m 3 ; and at least one wood veneer affixed on one surface of the core.
• the present disclosure relates to a method of making a plank, comprising: processing a composition comprising calcium carbonate and a core resin into a shape of a core; affixing at least one wood veneer having a first grain direction to at least one surface of the core; and affixing a second wood veneer having a second grain direction on top of the at least one wood veneer.
• the present disclosure relates to a method of making a plank, comprising: affixing at least one wood veneer having a first grain direction to at least one surface of a core comprising calcium carbonate and a core resin; and affixing a second wood veneer having a second grain direction on top of the at least one wood veneer.
• the present disclosure relates to a method of making a plank, comprising: applying a veneer resin on a surface of a core comprising calcium carbonate and a core resin; contacting a first surface of at least one wood veneer with said veneer resin to affix said at least one wood veneer to said core and to impregnate said at least one wood veneer with said veneer resin for a period of time of about 30 to about 90 min / mm of veneer thickness.
• the present disclosure relates to a method of making a plank, comprising: applying a veneer resin on a surface of a core comprising calcium carbonate and a core resin; contacting a first surface of at least one wood veneer with said veneer resin to affix said at least one wood veneer to said core and to impregnate said at least one wood veneer with said veneer resin for a period of time of about 30 to about 90 min / mm of veneer thickness; applying said veneer resin on a second surface of said at least one veneer;
• the present disclosure relates to a flooring plank including a core, wherein the core comprises at least 50 wt. % of calcium carbonate by weight.
• the present disclosure relates to a flooring plank comprising: a core comprising at least 50 wt. % calcium carbonate; and a wood veneer applied on one surface of the core.
• the present disclosure relates to a flooring plank comprising: a core comprising at least 50 wt. % calcium carbonate; a first wood veneer, wherein the first wood veneer is affixed to one surface of the core; and a second wood veneer, wherein the second wood veneer is affixed on top of the first wood veneer.
• the present disclosure relates to a method of making a plank, comprising: processing a composition comprising calcium carbonate and a core resin into a shape of a core; and affixing at least one wood veneer to at least one surface of the core.
• FIG. 1 A shows a schematic illustration of an example embodiment of a flooring plank in accordance with at least one embodiment
• FIG. 1 B shows a schematic illustration of the flooring plank of FIG. 1 A
• FIG. 2A shows a schematic illustration of an example embodiment of a flooring plank in accordance with at least one embodiment
• FIG. 2B shows a side view of the flooring plank of FIG. 1 A
• FIG. 3 shows a schematic illustration of an example embodiment of a flooring plank in accordance with at least one embodiment
• FIG. 4 shows a schematic illustration of an example embodiment of a flooring plank in accordance with at least one embodiment
• FIG. 5 shows a schematic illustration of an example embodiment of a flooring plank in accordance with at least one embodiment.
• the terms“including”,“comprising” and variations thereof mean“including but not limited to”, unless expressly specified otherwise. A listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise.
• the terms“a”,“an” and“the” mean“one or more”, unless expressly specified otherwise.
• the wording“and/or” is intended to represent an inclusive-or. That is,“X and/or Y” is intended to mean X or Y or both, for example. As a further example,“X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof.
• the flooring plank further includes at least one wood veneer, the wood veneer being affixed on one surface of the core.
• first grain direction and the second grain direction of the flooring plank are substantially orthogonal with respect to one another.
• the flooring plank has a swelling rate of less than about 0.5 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.4 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.3 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.2 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.1 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.5 % / 0.1 mm to about 0.01 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.2 % / 0.1 mm to about 0.02 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the flooring plank has a swelling rate of less than about 0.1 % / 0.1 mm to about 0.01 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• the at least one veneer comprises about 55 to about 95 % of a veneer resin by weight based on the total weight of the veneer.
• the at least one veneer comprises about 60 to about 85 % of a veneer resin by weight based on the total weight of the veneer.
• the at least one veneer comprises about 65 to about 80 % of a veneer resin by weight based on the total weight of the veneer.
• the at least one veneer comprises about 70 to about 80 % of a veneer resin by weight based on the total weight of the veneer.
• the flooring plank comprises about 55 to about 90% of a veneer resin by weight based on the total weight of the plank.
• the flooring plank comprises about 60 to about 85% of a veneer resin by weight based on the total weight of the plank.
• the flooring plank comprises about 65 to about 85% of a veneer resin by weight based on the total weight of the plank.
• the flooring plank comprises about 70% to about 80% of a veneer resin by weight based on the total weight of the plank.
• the flooring plank further comprises at least one wood veneer, the at least one wood veneer being affixed on one surface of the core.
• a varnish is applied to the wood veneer, so that the wood veneer is sandwiched between the core and the varnish.
• the flooring plank further includes a first wood veneer, wherein the first wood veneer is affixed to one surface of the core; and a second wood veneer, wherein the second wood veneer is affixed on top of the first wood veneer.
• the varnish comprises a non-toxic hypoallergenic material.
• the varnish comprises isocyanate.
• first wood veneer and the second wood veneer are substantially of the same species and thickness, such that the first wood veneer and the second wood veneer form a cross link to stabilize the warping of the flooring plank.
• a varnish is applied to the second wood veneer.
• At least one wood veneer has a thickness of about 0.2 mm to about 7 mm.
• At least one wood veneer has a thickness of about 0.5 mm to about 4 mm.
• the at least one wood veneer has a thickness of about 1 mm to about 3 mm.
• the at least one wood veneer has a thickness of about 0.5 mm to about 1 mm.
• the at least one wood veneer is affixed to the one surface of the core with a bonding material.
• at least one wood veneer is affixed to the one surface of the core with a resin comprising polyurethane.
• the core defines a tongue and groove locking mechanism.
• the core defines an elongated groove on at least one edge of the core and at least one elongated tongue on at least one other edge of the core.
• the core defines a click-lock locking mechanism.
• the core defines a click-lock glueless system on each edge of the core.
• a thickness of the core is about 1 mm to 30 mm.
• a thickness of the core is about 1 mm to 15 mm.
• a thickness of the core is about 1 mm to about 12 mm.
• a thickness of the core is about 2 mm to about 10 mm.
• a thickness of the core is about 3 mm to 8mm.
• a thickness of the core is about 2 mm.
• a thickness of the core is about 3 mm.
• a thickness of the core is about 6 mm.
• a thickness of the core is about 8 mm.
• the core has a density of at least 1000 kg/m 3 .
• the core has a density of about 1000 kg/m 3 to about 2600 kg/m 3 .
• the core has a density of at least 1500 kg/m 3 .
• the core has a density of at least 1800 kg/m 3 .
• the core has a density of about 1800 kg/m 3 .
• the core has a density of about 1500 kg/m 3 to about 2100 kg/m 3 .
• the core comprises at least 55 wt. % of calcium carbonate.
• the core comprises at least 60 wt. % of calcium carbonate.
• the core comprises at least 65 wt. % of calcium carbonate.
• the core comprises at least 70 wt. % of calcium carbonate.
• the core comprises at least 75 wt. % of calcium carbonate.
• the core comprises about 50 wt. % to about 90 wt. % of calcium carbonate.
• the core comprises about 60 wt. % to about 80 wt. % of calcium carbonate.
• the core comprises about 65 wt. % to about 75 wt. % of calcium carbonate.
• the core comprises about 68 wt. % to about 72 wt. % of calcium carbonate.
• the core comprises about 10 wt. % to about 40 wt. % of a core resin.
• the core comprises about 15 wt. % to about 35 wt. % of a core resin.
• the core comprises about 20 wt. % to about 30 wt. % of a core resin.
• the core comprises about 22 wt. % to about 28 wt. % of a core resin.
• the core comprises about 23 wt. % to about 27 wt. % of a core resin.
• the core resin comprises polyethylene (PE), polypropylene (PP), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyethylene terephthalate (PET) and/or polyvinylchloride (PVC).
• PE polyethylene
• PP polypropylene
• HDPE high-density polyethylene
• LDPE low-density polyethylene
• PET polyethylene terephthalate
• PVC polyvinylchloride
• the core resin comprises polyvinylchloride (PVC).
• the core resin further comprises at least one of: color powder;
• chlorinated polyethylene polyethylene
• calcium stearate chlorinated polyethylene
• the core comprises about 65 wt. % to about 75 wt. % calcium carbonate and about 20 wt. % to about 30 wt. % of resin.
• the core comprises about 70 wt. % calcium carbonate and about 25 wt. % PVC resin.
• the core comprises about 0.1 wt. % to about 1.0 wt. % of color powder, about 1 wt. % to about 2 wt. % of chlorinated polyethylene, about 1 wt. to about 2 wt. % polyethylene and about 0.1 wt. % to about 1.0 wt. % of calcium stearate.
• the core comprises about 0.5 wt. % color powder, about 1.3 wt % chlorinated polyethylene, about 1.5 wt. % polyethylene and about 0.6 wt. % calcium stearate.
• the core is a panel of at least 1200mm by at least 1200mm.
• the core is an extruded panel of about 1230mm by about 1280mm.
• the core is an extruded panel of about 1200mm by about 1200mm.
• the core is an extruded panel of about 209mm by about 1230mm.
• the plank is waterproof.
• the plank is resistant to moisture and/or heat.
• the method of making a plank comprises: processing a composition comprising calcium carbonate and a resin into a shape of a core; and affixing at least one wood veneer to at least one one surface of the core.
• the said at least one veneer wood veneer and said second wood veneer are affixed in such a manner that said first grain direction and said second grain direction are substantially orthogonal with respect to one another.
• the processing comprises extruding the core.
• said veneer resin is applied with a roller coater.
• the processing further comprises pressing said plank at temperature of about 40 S C to about 100 S C.
• the processing further comprises pressing said plank at temperature of about 50 S C to about 80 S C.
• the processing further comprises pressing said plank at temperature of about 60 S C to about 70 S C.
• said plank is pressed for a period of time of about 20 to about 60 min.
• said plank is pressed for a period of time of about 30 to about 50 min.
• said veneer resin is applied on said surface of said core in an amount of about 80 g to about 160 g/m2.
• said veneer resin is applied on said surface of said core in an amount of about 100 g to about 140 g/m2.
• said veneer resin is applied on said surface of said core in an amount of about 110 g to about 130 g/m2.
• said veneer resin is applied on said second surface of said at least one veneer in an amount of about 40 g to about 80 g/m2.
• said veneer resin is applied on said second surface of said at least one veneer in an amount of about 45 g to about 75 g/m2.
• said veneer resin is applied on said second surface of said at least one veneer in an amount of about 50 g to about 70 g/m2.
• said veneer resin is applied on said second surface of said at least one veneer in an amount of about 50 g to about 60 g/m2.
• a thickness of the core is about 1 mm to about 12 mm.
• the affixing comprises: affixing a first wood veneer having a first grain direction to one surface of the core; and affixing a second veneer having a second grain direction on top of the first wood veneer.
• the method further comprises: applying a first resin layer between the one surface of the core and the first wood veneer to affix the first wood veneer to the core; and applying a second resin layer between the first wood veneer and the second wood veneer to affix the second wood veneer to the first wood veneer, such that the first wood veneer and the second wood veneer form a cross link to stabilize the warping of the flooring plank.
• At least one of the first resin layer and the second resin layer comprise polyurethane.
• the method further comprises at least one of: trimming the plank; cutting the plank; profiling the plank; sanding the plank; and varnishing the plank with a varnish.
• the method comprises profiling a locking mechanism on at least one edge of the plank.
• the method comprises profiling a locking mechanism on each edge of the plank.
• the profiling comprises profiling an elongated groove on one edge of the core and /or an elongated tongue on one other edge of the core.
• the profiling comprises profiling a click-lock system on each edge of the core.
• the profiling comprises profiling a click-lock glueless system on each edge of the core.
• the method further comprises cutting the plank before profiling the plank.
• the varnish comprises a non-toxic hypoallergenic material.
• the varnish comprises isocyanate.
• the varnish comprises at least one anti-yellowing UV inhibiter.
• FIG. 1 A there is shown a schematic illustration of a flooring plank 1.
• the flooring plank 1 is shown in the form of a panel of 1280mm x 1230mm.
• FIG. 1 B there is shown another view of the flooring plank 1 of FIG. 1 A.
• the flooring plank includes a core.
• the core comprises calcium carbonate.
• a thickness of the core is about 1 mm to about 12 mm.
• a thickness of the core is about 2 mm to about 10 mm.
• a thickness of the core is about 3 mm to 8mm.
• a thickness of the core is about 2 mm.
• a thickness of the core is about 3 mm.
• a thickness of the core is about 6 mm.
• a thickness of the core is about 8 mm.
• the core has a density of at least 1800 kg/m 3 .
• the core has a density of about 1000 kg/m 3 to about 2600 kg/m 3 .
• the core has a density of at least 1500 kg/m 3 .
• the core has a density of about 1500 kg/m 3 to about 2100 kg/m 3 .
• the core comprises at least 55 wt. % of calcium carbonate.
• the core comprises at least 60 wt. % of calcium carbonate.
• the core comprises at least 65 wt. % of calcium carbonate.
• the core comprises at least 70 wt. % of calcium carbonate.
• the core comprises at least 75 wt. % of calcium carbonate.
• the core comprises about 50 wt. % to about 90 wt. % of calcium carbonate.
• the core comprises about 60 wt. % to about 80 wt. % of calcium carbonate.
• the core comprises about 65 wt. % to about 75 wt. % of calcium carbonate.
• the core comprises about 68 wt. % to about 72 wt. % of calcium carbonate.
• the core comprises about 10 wt. % to about 40 wt. % of a core resin.
• the core comprises about 15 wt. % to about 35 wt. % of a core resin.
• the core comprises about 20 wt. % to about 30 wt. % of a core resin.
• the core comprises about 22 wt. % to about 28 wt. % of a core resin.
• the core comprises about 23 wt. % to about 27 wt. % of a core resin.
• the core resin comprises polyvinylchloride (PVC).
• the core comprises at least one of: color powder; chlorinated polyethylene; polyethylene; and calcium stearate.
• the core comprises about 70 wt. % calcium carbonate and about 25 wt. % PVC core resin.
• the core comprises about 70 wt. % calcium carbonate and about 25 wt. % PVC core resin.
• the core comprises about 0.1 wt. % to about 1.0 wt. % of color powder, about 1 wt. % to about 2 wt. % of chlorinated polyethylene, about 1 wt. to about 2 wt. % polyethylene and about 0.1 wt. % to about 1.0 wt. % of calcium stearate.
• the core comprises about 0.5 wt. % color powder, about 1.3 wt % chlorinated polyethylene, about 1.5 wt. % polyethylene and about 0.6 wt. % calcium stearate.
• the core can be composed of about 70% calcium carbonate and about 25% PVC core resin.
• the core can be composed of about 0.5 % color powder, about 1.3% chlorinated polyethylene, about 1.5 % polyethylene and about 0.6% calcium stearate.
• the core can be stable to variations in humidity (RH 30%-70%).
• the core can provide greater strength over time.
• the core can be resistant to expansion and/or contraction, such as when atmospheric conditions vary.
• the core can be heat resistant.
• the core can be waterproof.
• the core can be rigid.
• the core can be dent resistant.
• FIG. 2A there is shown a schematic illustration of a flooring plank 21.
• FIG. 2B there is shown a side view of the flooring plank 21 of FIG. 2A.
• a mechanical locking system 23 is shown on FIG. 2B.
• the mechanical locking system 23 can be profiled on the core of the flooring plank 21.
• the mechanical locking system can be a click-lock glueless system on each edge of the core.
• the mechanical locking system can be a tongue and groove system.
• the flooring plank can have a groove extending along a first edge of the first panel and a tongue extending along a second edge of the first panel.
• the tongue can be on an opposing side of the edge of the panel having the groove.
• the groove has a groove profile and the tongue has a tongue profile such that the tongue and groove are capable of connecting with other panels having the groove profile and the tongue profile.
• the groove of a first panel is insertable into the tongue of a second panel while the second panel is lying flat on a surface to form a mechanical lock.
• a flooring plank includes a core composed of calcium carbonate and/or other materials as described above.
• the flooring plank also includes a wood veneer applied on one surface of the core.
• a varnish can be applied to the wood veneer, so that the wood veneer is sandwiched between the core and the varnish.
• the varnish can include a non-toxic hypoallergenic material.
• the varnish can include isocyanate.
• the wood veneer can have a thickness of about 0.2 mm to about 7 mm.
• the wood veneer can have a thickness of about 0.5 mm to about 4 mm.
• the wood veneer can have a thickness of about 1 mm to about 3 mm.
• the wood veneer can be affixed to the one surface of the core with a bonding material.
• the wood veneer can be affixed to the one surface of the core with resin comprising polyurethane.
• the flooring plank 30 includes a core 31 composed of calcium carbonate and/or other materials as described above, a first wood veneer 33 and a second wood veneer 35.
• the first wood veneer is affixed to the surface of the core by a layer of resin 32.
• the second wood veneer is affixed on top of the first wood veneer by a layer of resin 34.
• the resins 32 and 34 can be of polyurethane resin.
• Wood grain refers to the longitudinal orientation of the wood fibers.
• the directions of their respective grain may be a factor for stabilizing the warping of the flooring plank.
• the first wood veneer can have a first grain direction.
• the first grain direction can be horizontal.
• the second wood veneer can have a second grain direction.
• the second grain direction can be vertical.
• the second wood veneer can be at a direction that is at 90 degrees from the first grain direction of the first wood veneer.
• first wood veneer and the second wood veneer can be of the same species and thickness.
• first wood veneer and the second wood veneer can be of oak.
• first wood veneer and the second wood veneer can be of maple.
• the second wood veneer can be affixed on the first wood veneer, such that the first wood veneer and the second wood veneer form a cross link to stabilize the warping of the flooring plank.
• this tension can force the first wood veneer to take a curve shape when affixed to the core.
• this tension can force the first wood veneer to warp.
• this tension can force the first wood veneer to warp for about +5mm in the vertical direction.
• this tension can be created because wood can be hygroscopic.
• wood tends to absorb moisture from the air.
• this second tension can be in the direction of the second grain direction.
• this second tension can counterbalance the tension created by the first wood veneer.
• this second tension can be opposed to the first tension to fold down the warping of the first wood veneer.
• the second tension can be applied to the first wood veneer to fold down the first wood veneer by -5mm, such the warping of the flooring plank is cancelled.
• the first wood veneer and the second wood veneer can form a cross link to stabilize the warping of the flooring plank.
• first wood veneer and the second wood veneer can be two crossed wood veneer plies of the same species and thickness that are applied on an extruded core to stabilize the warping of flooring plank.
• a varnish can be applied to the second wood veneer.
• the varnish can be a sealer.
• applying the varnish to the second wood veneer can make the flooring plank water resistant.
• applying the varnish to the second wood veneer can make the flooring plank heat resistant.
• applying the varnish to the second wood veneer can make the flooring plank moisture resistant.
• the varnish can include a non-toxic hypoallergenic material.
• the varnish can include isocyanate.
• a color or pattern can be applied to the varnish for aesthetic purposes.
• the flooring plank 40 includes a core 41 composed of calcium carbonate and/or other materials as described above, a first wood veneer 43 and a second wood veneer 45.
• the first wood veneer is affixed to the surface of the core by a layer of resin 42.
• the second wood veneer is affixed on top of the first wood veneer by a layer of resin 44.
• the resins 42 and 44 can be of polyurethane resin.
• a varnish 46 can be applied to second wood veneer 45.
• the varnish can include comprises a non-toxic hypoallergenic material.
• the varnish can include isocyanate.
• the varnish can integrate an anti-yellowing UV inhibiter.
• the varnish can offer an increased resistance to surface wear.
• a flooring plank can include a core composed of at least 70 % calcium carbonate; a first wood veneer having a first grain direction, wherein the first wood veneer is affixed to one surface of the core; a second wood veneer having a second grain direction, wherein the second wood veneer is affixed on top of the first wood veneer, such that the first wood veneer and the second wood veneer form a cross link to stabilize the warping of the flooring plank; and a varnish applied to the second veneer.
• the varnish can include a non-toxic hypoallergenic material.
• the varnish can include isocyanate.
• the flooring plank can be waterproof.
• the flooring plank can be resistant to moisture and/or heat.
• the flooring plank 140 includes a core 141.
• the core can comprise calcium carbonate and/or other materials as described above.
• the flooring plank 140 can also include a wood veneer 143.
• a varnish layer 146 can be applied to the wood veneer 143.
• the core can be stable to variations in humidity (RH 30%-70%).
• the core can provide greater strength over time.
• the core can be resistant to expansion and/or contraction, such as when atmospheric conditions vary.
• the core can be heat resistant.
• the core can be waterproof.
• the core can be rigid.
• the core can be dent resistant.
• the wood veneer 143 can be affixed to the surface of the core by a bonding material, such as a layer of resin.
• the resin can comprise polyurethane.
• the wood veneer can be of multiple colours.
• the veneer can be designed with micro-v four-sided bevels.
• the veneer can embody the authenticity and craftsmanship of real wood due to the micro-v joints and evenly applied stain.
• the wood veneer 143 can include 2 wood veneers which have been affixed together.
• the wood veneer 143 can include two crossed wood veneer plies of the same species and thickness.
• such configuration can stabilize the warping of the flooring plank.
• the varnish 146 can be applied to the wood veneer 143.
• the varnish can include comprises a non-toxic hypoallergenic material.
• the varnish can include isocyanate.
• the varnish can include a non-toxic hypoallergenic finish with antimicrobial agent incorporated.
• the varnish can integrate an anti-yellowing UV inhibiter.
• the varnish can offer an increased resistance to surface wear.
• the varnish can be durable.
• the varnish can offer long lasting performance.
• a method of making a flooring plank can include: processing a composition into a shape of a core, wherein the core is composed of calcium carbonate; and affixing at least one wood veneer to one surface of the core.
• the processing can include extruding the core.
• the core can further be composed of PVC core resin; color powder; chlorinated polyethylene; polyethylene; and calcium stearate.
• the core can be extruded in a panel of at least 1230mm x 1280mm.
• the affixing can include affixing a first wood veneer having a first grain direction to one surface of the core and affixing a second veneer having a second grain direction on top of the first wood veneer.
• the method can further include applying a first resin layer between the one surface of the core and the first wood veneer to affix the first wood veneer to the core; and applying a second resin layer between the first wood veneer and the second wood veneer to affix the second wood veneer to the first wood veneer, such that the first wood veneer and the second wood veneer form a cross link to stabilize the warping of the flooring plank.
• the first resin layer and the second resin layer can include
• the method can further include: trimming the plank; cutting the plank; profiling the plank; sanding the plank; and varnishing the plank with a varnish.
• profiling the flooring plank can include profiling an elongated groove on one edge of the core and an elongated tongue on one other edge of the core.
• profiling the flooring plank can include profiling a click-lock design on each edge of the core.
• profiling the flooring plank can include profiling a glueless locking mechanism each edge of the core.
• the varnish can include a non-toxic hypoallergenic material.
• the varnish can include isocyanate.
• the flooring plank can be easy to install.
• the flooring plank can be installed with drop lock installation.
• the flooring plank may be used in kitchens, bathrooms and
• the flooring plank may be installed over subfloors with minor imperfections.
• the present subject matter relates to a method of making a plank that will provide a rigid waterproof hardwood flooring plank that will use a wide variety of wood species on a calcium carbonate composite core.
• the core can be of more than 3mm to 8mm in thickness.
• the core can be water, moisture and heat resistant.
• the core will present a density over 1800 kg/m 3 .
• the distinct coloured composite core content presents more than 70% of calcium carbonate extruded in a panel of more than 1230mm x 1280mm to affix wood veneer on its surface of more than 0.5mm to 4mm thick in sheet or coupon.
• the veneer resin comprises polyurethane.
• the at least one wood veneer has a thickness of about 0.2 mm to about 7 mm.
• the at least one wood veneer has a thickness of about 0.5 mm to about 4 mm.
• the at least one wood veneer has a thickness of about 1 mm to about 3 mm.
• the at least one wood veneer has a thickness of about 0.5 mm to about 1 mm.
• the veneer can be impregnated with more than half of its thickness with adapted polyurethane resin based on wood species absorption to be applied with pressure and heat on one surface of the core after it has been extruded.
• two crossed wood veneer plies of the same species and thickness can be applied on one face of the extrusion to stabilize the warping of the panel. All components can be assembled to cover the surface of the panel that will be cut in plank, profiled, sanded, brushed, scraped and finally covered by a stained or natural water-based varnish that will incorporate isocyanate and impregnate the other half of the thickness of the veneer ply to increase the water protection.
• plank By its density and rigidity, the plank can be profiled with a regular tongue and groove profile or a click-lock resinless system on each edge.
• the plank can be resistant to moisture or water absorption.
• the plank can be resistant to heat and heat variations.
• the plank can be resistant to expansion and/or contraction which would result in peaks or gaps.
• said plank has a swelling rate of less than about 0.5 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• said plank has a swelling rate of less than about 0.4 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• said plank has a swelling rate of less than about 0.3 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• said plank has a swelling rate of less than about 0.2 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.
• said plank has a swelling rate of less than about 0.1 % / 0.1 mm of thickness of wood veneer, measured according to EN 13329.

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