# US 10,479,057 B2 · Polymeric substrates with an improved thermal expansion coefficient and a method for producing the same

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- Number: US 10,479,057 B2
- Document ID: US10479057B2
- Status: Granted
- Kind: B2
- Application number: 15/552,092
- Filed: 2016-01-18
- Published: 2018-02-15
- Granted: 2019-11-19
- Earliest claimed: 2015-01-18
- Assignees: Magma Flooring LLC
- Applicants: Magma Flooring LLC
- Inventors: Greggory S Bennett; Jeffrey Jacob Cernohous; Vance Warren Zins; Todd Richard Samstrom
- Web page: https://patentgrep.com/patent/US10479057B2

## CPC

- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B29C 70/506: {and impregnating by melting a solid material, e.g. sheet, powder, fibres (B29C70/508 takes precedence)}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- C08J 5/043: {with glass fibres}
- C08J 5/18: Manufacture of films or sheets
- C08K 3/00: Use of inorganic substances as compounding ingredients
- C08K 3/01: characterized by their specific function
- C08K 5/00: Use of organic ingredients
- C08K 5/0008: {Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59}
- C08K 7/14: Glass
- E04C 1/00: Building elements of block or other shape for the construction of parts of buildings (of relatively thin form E04C2/00; structural elongated elements designed for load-supporting E04C3/00, e.g. columns or pillars E04C3/30; manufacture or material of building bricks, stones, or the like B28, C03, C04; paving elements E01C; general building constructions E04B, e.g. walls E04B2/00, floors E04B5/00, roofs E04B7/00, ceilings E04B9/00; {roof coverings E04D; coverings for walls or ceilings E04F13/00; floorings E04F15/00;} structural elements specially designed for built-in conduit shafts E04F17/00; {elements for buildings for particular purposes E04H7/00}; special elements for building ovens or furnaces F24B, F27D)
- E04C 2/22: reinforced {(E04C2/205 takes precedence)}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2264/04: Cellulosic particles, e.g. rayon
- B32B 2264/06: Vegetal particles
- B32B 2264/067: Wood particles
- B32B 2264/10: Inorganic particles
- B32B 2307/30: having particular thermal properties
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/732: Dimensional properties
- B32B 2419/04: Tiles for floors or walls
- C08J 2323/06: Polyethene
- C08J 2323/12: Polypropene
- C08J 2327/06: Homopolymers or copolymers of vinyl chloride
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)

## Abstract

A substrate and method for providing a thermoplastic composite having a fiberglass mat embedded within a thermoplastic polymer. The characteristics of the fiberglass mat combined with a thermal compression bonding method allow for a substantially improved and desirable thermal expansion coefficient over conventionally filled thermoplastic substrates or other fiberglass reinforced thermoplastics.

## Claims

### Claim 1

A substrate comprising: a thermoplastic composite having a fiberglass mat embedded in a thermoplastic resin, wherein the fiberglass mat has a basis weight of 76 to 500 g/m2 and about 20 to about 3000 fiberglass intersections per cm2, and wherein the thermoplastic composite possesses (i) a Thermal Expansion Coefficient of ⅓ or less than that of a substrate derived from a neat embodiment of the thermoplastic resin, or (ii) a Thermal Expansion Coefficient of 50*10−6 m/(m*° C.) or lower.

### Claim 2 (depends on 1)

A substrate according to claim 1, wherein the thermoplastic composite has a Thermal Expansion Coefficient of 40*10−6 m/(m*° C.) or lower.

### Claim 3 (depends on 1)

A substrate according to claim 1, wherein the thermoplastic composite meets the specification of flatness in the flooring industry, with gaps measured over a 45 cm span of less than 0.35 cm.

### Claim 4 (depends on 1)

A substrate according to claim 1, further comprising one or more fillers in the thermoplastic composite.

### Claim 5 (depends on 4)

A substrate according to claim 4, wherein the one or more fillers comprise cellulose, calcium carbonate, volcanic ash, expanded volcanic ash, wood flour or rice hulls.

### Claim 6 (depends on 4)

A substrate according to claim 4, wherein the one or more fillers include a mineral filler or an organic filler.

### Claim 7 (depends on 1)

A substrate according to claim 1, wherein the thermoplastic resin comprises a polyolefin and the thermoplastic composite has a thickness of 2 mm to 7 mm and a Thermal Expansion Coefficient of 50*10−6 m/(m*° C.) or lower.

### Claim 8 (depends on 1)

A substrate according to claim 1, wherein the thermoplastic resin comprises a polypropylene, polyethylene, polyolefin copolymer, polyvinyl chloride, polyethylene terephthalate, polyamide, a polyolefin from a hydropulping process, or combination thereof.

### Claim 9 (depends on 1)

A substrate according to claim 1, wherein the thermoplastic composite has a basis weight between 500 g/m2 to 10,000 g/m2.

### Claim 10 (depends on 1)

A substrate according to claim 1, further comprising at least one additional layer bonded to the thermoplastic composite to form a multilayered article.

### Claim 11

An article comprising a substrate derived from thermal compression bonding a thermoplastic resin with a fiberglass mat and optionally one or more fillers, wherein the fiberglass mat has a basis weight of 76 to 1250 g/m2 and about 20 to about 3000 fiberglass intersections per cm2, and wherein the thermoplastic composite possesses a Thermal Expansion Coefficient of ⅓ or less than that of a substrate derived from a neat embodiment of the thermoplastic resin, or (ii) a Thermal Expansion Coefficient of 50*10−6 m/(m*° C.) or lower.

### Claim 12

A method comprising: (a) scattering a thermoplastic resin with optionally one or more fillers onto a fiberglass mat positioned on a first rotating belt, wherein the fiberglass mat has a weight of at least 76 up to 1250 g/m2 and about 20 to about 3000 fiberglass intersections per cm2 (b) thermal compression bonding the thermoplastic resin with optionally one or more fillers and the fiberglass mat between the first rotating belt with a second rotating belt to form a substrate, wherein the substrate possesses (i) a Thermal Expansion Coefficient of ⅓ or less than that of a substrate derived from a neat embodiment of the thermoplastic resin, or (ii) a Thermal Expansion Coefficient of 50*10−6 m/(m*° C.) or lower.

### Claim 13 (depends on 12)

A method according to claim 12, wherein the substrate possesses a Thermal Expansion Coefficient of 40*10−6 m/(m*° C.) or lower.

### Claim 14 (depends on 12)

A method according to claim 12, further comprising first scattering an additional layer of a thermoplastic resin with optionally one or more fillers onto the first rotating belt before positioning the fiberglass mat onto the first rotating belt.

### Claim 15 (depends on 14)

A method according to claim 14, wherein the thermoplastic resin has a particle size of 0.05 cm to 0.5 cm.

### Claim 16 (depends on 12)

A method according to claim 12, wherein thermal compression bonding is performed on a continuous double belt press.

### Claim 17 (depends on 12)

A method according to claim 12, wherein the thermoplastic resin comprises a polypropylene, polyethylene, polyolefin copolymer, polyvinyl chloride, polyethylene terephthalate, polyamide, polyolefin from a hydropulping process, or combination thereof.

### Claim 18 (depends on 12)

A method according to claim 12, further comprising treating a surface of the substrate.

### Claim 19 (depends on 18)

A method according to claim 18, wherein treating comprises plasma treatment, corona treatment, silane treatment, use of primer materials or heat treatment.

### Claim 20 (depends on 12)

A method according to claim 12, further comprising bonding at least one additional layer to the substrate to form a multilayered article.