Systems and methods for producing durable, dimensionally stable, extruded sheet goods having a desired specific gravity
AssigneeGolconda Holdings, LLC
InventorShane S. LeBlanc
Life of this patent
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Abstract
The present invention provides a system, method, and apparatus for producing a dimensionally stable extruded board product for use in surface coverings. The board product may be a basalt casting powder-based product for use as a substrate for wall or other surface coverings or may be used as a core layer in a modular floor covering unit. The modular floor covering unit comprises multiple layers. The layers are a thin cut stone veneer layer, a core layer with a density similar to that of the thin cut stone veneer layer, and an optional magnetically receptive underlayment layer. Other layers or combinations of layers may also be used.
Claims24
An extruded, dimensionally stable board product comprising:
- a primary material comprised of water-insoluble, non-fibrous stone powder or dust;
- a filler material;
- a foaming agent;
- a stabilizer comprising calcium zinc;
- and
- a binding material;
- wherein the board product is formed by mixing the primary material, the filler material, the foaming agent, the stabilizer, and the binding material in a high speed and high temperature mixer to form a mixture, and extruding the mixture to form an extruded product;
- and
- wherein the board product has a specific gravity of between 2.0 and 4.0;
- and
- wherein the board product further comprises:
- at least 45% of the binding material;
- at least 15% of the filler material;
- at least 30% of the primary material;
- at least 0.5% of the foaming agent;
- and
- at least 2% of the stabilizer.
A lightweight hybrid floor covering unit, the floor covering unit comprising:
- a thin cut stone veneer top layer having a first specific gravity and a thickness of approximately 0.125 inch or less;
- and
- a shock absorbing core layer comprised of non-fibrous stone powder or dust and having a second specific gravity in equilibrium with the first specific gravity of the thin cut stone veneer top layer;
- wherein each of the first specific gravity and the second specific gravity represents the density of each respective layer relative to a baseline material;
- wherein the first specific gravity of the thin cut stone veneer top layer and the second specific gravity of the shock absorbing core layer are closely matched to prevent cracking and damage to the thin cut stone layer normally associated with wear, impacts and shocks;
- and
- wherein the combined thin cut stone veneer top layer and shock absorbing core layer result in the floor covering unit having a specific gravity of 2.0 to 4.0;
- and
- wherein the shock absorbing core layer is a dimensionally stable board product comprising:
- a primary material;
- a filler material;
- a foaming agent;
- a stabilizer;
- and
- a binding material;
- and
- wherein the dimensionally stable board product further comprises:
- at least 45% of the binding material;
- at least 15% of the filler material;
- at least 30% of the primary material;
- at least 0.5% of the foaming agent;
- and
- at least 2% of the stabilizer.
Dependencies are inferred from the claim text.