# US 10,501,945 B2 · Polymeric composites, resulting panels, and method for producing the same

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- Number: US 10,501,945 B2
- Document ID: US10501945B2
- Status: Granted
- Kind: B2
- Application number: 14/404,544
- Filed: 2013-05-30
- Published: 2015-04-30
- Granted: 2019-12-10
- Earliest claimed: 2012-05-30
- Assignees: Magma Flooring LLC
- Applicants: Magma Flooring LLC
- Inventors: Jeffrey Jacob Cernohous; Greggory S Bennett; Brandon Cernohous; Garrett S Van Gorden
- Web page: https://patentgrep.com/patent/US10501945B2

## CPC

- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B29B 17/0042: {for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic}
- B29C 43/003: {characterised by the choice of material}
- B29C 43/24: Calendering
- B29C 43/305: {Making multilayered articles}
- B29C 43/32: Component parts, details or accessories; Auxiliary operations
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 37/182: {one or more of the layers being plastic}
- B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence)
- C08J 5/00: Manufacture of articles or shaped materials containing macromolecular substances (manufacture of semi-permeable membranes B01D67/00 - B01D71/00)
- C08K 3/013: Fillers, pigments or reinforcing additives
- C08K 3/22: of metals
- C08K 3/26: Carbonates; Bicarbonates
- C08K 3/36: Silica
- C08K 7/02: Fibres or whiskers
- C08K 7/14: Glass
- C08K 7/26: Silicon- containing compounds
- C08K 11/00: Use of ingredients of unknown constitution, e.g. undefined reaction products
- C08L 23/06: Polyethylene
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- B29K 2023/0633: {LDPE, i.e. low density polyethylene}
- B29K 2023/12: {PP, i.e. polypropylene}
- B29K 2105/16: Fillers
- B29K 2105/26: Scrap {or recycled material}
- B29K 2509/00: Use of inorganic materials not provided for in groups {B29K2503/00 - B29K2507/00,} as filler
- B29L 2007/002: {Panels; Plates; Sheets}
- B29L 2009/00: Layered products
- B32B 37/12: characterised by using adhesives
- B32B 2264/02: Synthetic macromolecular particles
- B32B 2264/10: Inorganic particles
- B32B 2264/12: Mixture of at least two particles made of different materials
- B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material
- B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips
- B32B 2305/70: Scrap or recycled material
- B32B 2323/04: Polyethylene
- B32B 2323/10: Polypropylene
- B32B 2419/04: Tiles for floors or walls
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- C08J 2323/06: Polyethene
- C08J 2323/12: Polypropene
- C08J 2497/02: Lignocellulosic material, e.g. wood, straw or bagasse
- C08K 2003/2206: {of calcium, strontium or barium}
- C08K 2003/265: {Calcium, strontium or barium carbonate}
- C08L 2205/16: Fibres; Fibrils
- C08L 2207/066: LDPE (radical process)
- C08L 2207/20: Recycled plastic
- Y02W 30/62: Plastics recycling; Rubber recycling
- Y10T 428/24149: Honeycomb-like
- Y10T 428/24157: Filled honeycomb cells [e.g., solid substance in cavities, etc.]
- Y10T 428/249991: Synthetic resin or natural rubbers
- Y10T 428/28: Web or sheet containing structurally defined element or component and having an adhesive outermost layer
- Y10T 428/2848: Three or more layers
- Y10T 428/3167: Of cork
- Y10T 428/31678: Of metal
- Y10T 428/31913: Monoolefin polymer
- Y10T 428/31938: Polymer of monoethylenically unsaturated hydrocarbon
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A polymeric composite derived from a reclaimed polymeric material. The polymeric composite in particulate form can be thermally compressed into panels and other embodiments that require a component that possesses sufficient mechanical strength and moisture resistance. In certain embodiments, the panel may be utilized as one layer in a multilayered article.

## Claims

### Claim 1

A method comprising thermal compression bonding (i) a polymeric material from a hydropulping process, or (ii) a composite of a reclaimed polymeric material, a high aspect ratio filler, and a lightweight filler to form a substrate; and applying an adhesive composition that is formed as a layer on the substrate.

### Claim 2

A method comprising thermal compression bonding (i) a polymeric material from a hydropulping process, or (ii) a composite of a reclaimed polymeric material, a high aspect ratio filler, and a lightweight filler to form a substrate; and surface treating the substrate.

### Claim 3 (depends on 2)

A method according to claim 2, wherein treating comprises plasma treatment, silane treatment, heat treatment, corona treatment, or combinations thereof.

### Claim 4

A method comprising:
(a) scattering onto a first rotating belt a (i) a polymeric material from a hydropulping process, or (ii) a reclaimed polymeric material and a lightweight filler, and optionally an organic filler or inorganic filler or combinations thereof, and
(b) thermal compression bonding the composite between the first rotating belt with a second rotating belt to form a substrate.

### Claim 5 (depends on 4)

A method according to claim 4, further comprising scattering a layer of a second compound onto the composite prior to thermal compression bonding to form a multilayered article.

### Claim 6 (depends on 4)

A method according to claim 4, further comprising one or more additives selected from antioxidants, light stabilizers, fibers, blowing agents, foaming additives, antiblocking agents, heat stabilizers, impact modifiers, biocides, compatibilizers, flame retardants, plasticizers, tackifiers, colorants, processing aids, lubricants, adhesion promoting agents, pigments or combinations thereof.

### Claim 7

A method according to 40, further comprising blending the one or more additives with (i) the polymeric material from a hydropulping process, or (ii) the reclaimed polymeric material and lightweight filler, and optionally the organic filler or inorganic filler or combinations thereof, prior to thermal compression bonding.

### Claim 8

A method comprising thermal compression bonding (i) a polymeric material from a hydropulping process, or (ii) a composite of a reclaimed polymeric material, a high aspect ratio filler, and a lightweight filler to form a substrate; and applying an adhesive composition that is formed as a layer on the substrate, or surface treating the substrate.

### Claim 9 (depends on 8)

The method according to claim 8, wherein the composite is co-scattered with another polymeric material, and upon thermal compression bonding forms a multilayered substrate.

### Claim 10 (depends on 8)

The method according to claim 8, further comprising bonding an aesthetic layer, a reinforcing layer, a sound dampening layer, an adhesive layer, a bondable layer, a support layer, a printable layer, polymeric layer, reflective layer, or combinations thereof to the substrate.

### Claim 11

The method according to 42, further comprising blending the one or more additives with (i) the polymeric material from a hydropulping process, or (ii) the reclaimed polymeric material and lightweight filler prior to thermal compression bonding.

### Claim 12

The method according to 11, wherein the one or more additives is selected from antioxidants, light stabilizers, fibers, blowing agents, foaming additives, antiblocking agents, heat stabilizers, impact modifiers, biocides, compatibilizers, flame retardants, plasticizers, tackifiers, colorants, processing aids, lubricants, adhesion promoting agents, pigments or combinations thereof.

### Claim 13 (depends on 8)

The method according to claim 8, wherein the lightweight filler is expanded volcanic ash, perlite, pumice, cenospheres, glass microspheres, ceramic microspheres, polymeric microspheres, foamed polymeric beads, cellulosic fiber, or combination thereof.

### Claim 14 (depends on 8)

The method according to claim 8, wherein the substrate further comprises one or more of an inorganic filler, organic filler, a coupling agent, a desiccant, a lubricant, or an antimicrobial.

### Claim 15 (depends on 8)

The method according to claim 8, wherein the substrate exhibits water absorption of less than 10% as indicated after submersion in water for twenty-four hours at room temperature.

### Claim 16 (depends on 8)

The method according to claim 8, wherein the substrate is a flooring substrate, a roofing panel, a marine panel, a concrete form, wall panel, door panel, automotive panel, aerospace panel, or a signage panel.

### Claim 17 (depends on 8)

The method according to claim 8, wherein a flexural modulus, a coefficient of thermal expansion, or an impact strength of the substrate in a machine direction is within at least 30% of a flexural modulus, a coefficient of thermal expansion, or an impact strength of the substrate in a transverse machine direction.

### Claim 18 (depends on 8)

The method according to claim 8, wherein the substrate exhibits a thermal expansion of less than 0.5% according to a Thermal Expansion Test Method.

### Claim 19 (depends on 8)

The method according to claim 8, wherein the reclaimed polymeric material includes reclaimed polymers from hydropulping processes, low density polyethylene, polymers from agricultural film waste streams, polymers from municipal waste streams, polymers from medical waste streams, or combinations thereof.

### Claim 20 (depends on 8)

The method according to claim 8, wherein the substrate exhibits at least two of a specific gravity of about 0.5 to 1.6 g/cm3, a coefficient of thermal expansion of less than 70 μm/m/K, a thermal expansion of less than 0.5% according to the Thermal Expansion Test Method, and a water absorption of less than 10% as indicated after submersion in water for twenty-four hours at room temperature.