# US 11,306,487 B2 · Rigid polymeric modular flooring plank, method of making same, and method of using same

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- Number: US 11,306,487 B2
- Document ID: US11306487B2
- Status: Granted
- Kind: B2
- Application number: 16/950,063
- Filed: 2020-11-17
- Published: 2021-06-03
- Granted: 2022-04-19
- Earliest claimed: 2019-12-02
- Assignees: Mannington Mills, Inc.
- Applicants: Mannington Mills, Inc.
- Inventors: Brian Kuritz; Joseph J. Delarso, Jr.; Terry Marchetta; James Michael Tuley
- Web page: https://patentgrep.com/patent/US11306487B2

## CPC

- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 23/04: comprising such {cellulosic plastic} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/08)}
- B32B 23/046: {of natural rubber or synthetic rubber}
- B32B 23/08: of synthetic resin
- B32B 23/18: Fillers
- B32B 23/20: comprising esters
- B32B 25/02: with fibres or particles {being present as additives in the layer}
- B32B 25/042: {of natural rubber or synthetic rubber}
- B32B 25/08: of synthetic resin
- B32B 25/12: comprising natural rubber
- B32B 25/14: comprising {synthetic rubber copolymers (B32B25/18 and B32B25/20 take precedence)}
- B32B 25/16: comprising polydienes {homopolymers} or poly-halodienes {homopolymers (B32B25/12 takes precedence)}
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/18: characterised by the use of special additives
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 27/281: {comprising polyimides}
- B32B 27/283: {comprising polysiloxanes}
- B32B 27/285: {comprising polyethers}
- B32B 27/288: {comprising polyketones}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/40: comprising polyurethanes
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- E04F 15/02033: {Joints with beveled or recessed upper edges}
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2250/24: All layers being polymeric
- B32B 2250/44: Number of layers variable across the laminate
- B32B 2255/12: on paper layer
- B32B 2255/26: Polymeric coating
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2264/0214: Particles made of materials belonging to B32B27/00
- B32B 2264/062: Cellulose particles, e.g. cotton
- B32B 2264/067: Wood particles
- B32B 2264/10: Inorganic particles
- B32B 2264/101: Glass
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2264/12: Mixture of at least two particles made of different materials
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/402: Coloured
- B32B 2307/50: having particular mechanical properties
- B32B 2307/536: Hardness
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/732: Dimensional properties
- B32B 2419/04: Tiles for floors or walls
- B32B 2451/00: Decorative or ornamental articles
- E04F 2201/0107: by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
- E04F 2201/0153: by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
- E04F 2201/023: with a continuous tongue or groove
- E04F 2201/043: with tongues and grooves being formed by projecting or recessed parts of the panel layers
- E04F 2203/02: having particular shapes, other than square or rectangular, e.g. triangular, hexagonal, circular, irregular
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A rigid polymeric modular flooring plank can be one continuous piece having a top surface, a bottom surface and multiple sides defining the edges of said rigid polymeric modular flooring plank. The rigid polymeric modular flooring plank can include the appearance of multiple tiles or one tile as part of the top surface, with each of the multiple tiles having multiple simulated sides and a decorative surface, and each tile is completely surrounded by simulated grout lines that have a depth and either have a full width W or a half width ½W. Any simulated grout line that is located at any of said multiple sides has the half width and all other simulated grout lines have the full width. The rigid polymeric modular flooring plank has at least a polymeric base layer, a decorative layer, and a wear layer located above the decorative layer.

## Claims

### Claim 1

A flooring system comprising at least a first rigid polymeric modular flooring plank and a second rigid polymeric modular flooring plank of the same size and shape as the first rigid polymeric modular flooring plank, said first rigid polymeric modular flooring plank and said second rigid polymer flooring plank are each one continuous piece having a top surface, a bottom surface and multiple sides defining the edges of said rigid polymeric modular flooring plank, each of the edges being absent of a mechanical locking design, and the rigid polymeric modular flooring plank includes the appearance of one tile or multiple tiles as part of said top surface with each of said one tile or multiple tiles having multiple edges and a decorative surface and each of said one or multiple tiles completely surrounded by simulated grout lines that have a depth and either have a full width W or a half width ½W, wherein any simulated grout line that is located at any of said one or multiple sides has said half width and all other simulated grout lines have said full width, wherein said first and second rigid polymeric modular flooring plank comprises a polymeric base layer, a decorative layer and at least one wear layer located above said decorative layer, wherein said simulated grout lines are formed by removing portions of at least said wear layer and decorative layer, and
wherein the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank are arranged adjacent to one another, such that one or more of the free edges of the first rigid polymeric modular flooring plank and one or more of free edges of the second rigid polymeric modular flooring plank form a simulated grout line having the depth and full width W of the simulated grout lines having said full width W, and a filler material is present in said simulated grout line so as to fill said simulated grout line.

### Claim 2 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has a corresponding shape such that an outer edge thereof abuts the second rigid polymeric modular flooring plank of the same size and shape of the first rigid polymeric modular flooring plank.

### Claim 3 (depends on 1)

The flooring system of claim 1, wherein said first rigid polymeric modular flooring plank is a luxury vinyl plank.

### Claim 4 (depends on 1)

The flooring system of claim 1, wherein the multiple tile edges include a bevel surface.

### Claim 5 (depends on 4)

The flooring system of claim 4, wherein said bevel surface has a width of from about 0.01 mm to about 0.1 mm.

### Claim 6 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has a thickness, and the simulated grout lines having the full width have a width of from about 0.05 inch to about 0.2 inch and a depth in relation to the rigid polymeric modular flooring plank thickness of from about 2% to about 50% of the thickness of the first rigid polymeric modular flooring plank.

### Claim 7 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has a stiffness, as measured by ASTM D1037-12 of from about 1 GPa to about 15 GPa.

### Claim 8 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has a stiffness, as measured by ASTM D1037-12 of from about 1.5 GPa to about 5 GPa.

### Claim 9 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has a thickness of from about 4 mm to 15 mm.

### Claim 10 (depends on 1)

The flooring system of claim 1, wherein said multiple tiles are positioned in a common plane.

### Claim 11 (depends on 1)

The flooring system of claim 1, wherein the simulated grout lines have a bottom and said bottom is located in the polymeric base layer.

### Claim 12 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has a surface area of from about 1 square foot to about 4 square feet.

### Claim 13 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank has the appearance of from 1 to 12 tiles and each tile have a cross-sectional area of from about 1.5 square inches to 300 square inches.

### Claim 14 (depends on 1)

The flooring system of claim 1, wherein the first rigid polymeric modular flooring plank is a form of a circle, a triangle, a square, a non-square rectangle, a pentagon, a hexagon, or a tri-hexagon.

### Claim 15 (depends on 1)

The flooring system according to claim 1, wherein the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank are arranged adjacent to one another in a gap-free juxtaposition.

### Claim 16 (depends on 1)

A method of installing the flooring system of claim 1, comprising:
placing, on a floor, the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank,
aligning the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank together such that the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank are arranged adjacent to one another in a gap-free juxtaposition, and
filling the simulated grouting lines with the filler material.

### Claim 17 (depends on 16)

The method of claim 16, wherein said aligning is carried out without a spacer located between the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank.

### Claim 18 (depends on 16)

The method of claim 16, further comprising:
prior to said placing, coating the floor with an adhesive composition, wherein
upon said placing and aligning, the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank are at least partly immobilized by the adhesive composition.

### Claim 19 (depends on 16)

The method of claim 16, wherein at least one of the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank comprises a first adhesive layer, and, optionally, a second adhesive layer, and
wherein the method further comprises:
adhering the first rigid polymeric modular flooring plank and the second rigid polymeric modular flooring plank by pressing the first adhesive layer and the optional second adhesive layer against the floor.