# US 11,898,034 B2 · Homogeneous sheet excluding polyvinyl chloride

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- Number: US 11,898,034 B2
- Document ID: US11898034B2
- Status: Granted
- Kind: B2
- Application number: 18/093,506
- Filed: 2023-01-05
- Published: 2023-07-13
- Granted: 2024-02-13
- Earliest claimed: 2020-01-07
- Assignees: Ahf, LLC
- Applicants: Ahf, LLC
- Inventors: Water Zhang
- Web page: https://patentgrep.com/patent/US11898034B2

## CPC

- B29B 7/90: Fillers or reinforcements {, e.g. fibres}
- C08L 75/06: from polyesters
- B29B 7/002: {Methods (chemical aspects C08J3/00)}
- B29B 7/7461: {Combinations of dissimilar mixers}
- B29B 7/7495: {for mixing rubber}
- B29C 43/24: Calendering
- B29C 43/30: Making multilayered or multicoloured articles {(B29C43/26 takes precedence)}
- B29C 48/0011: {combined with compression moulding}
- B29C 48/08: flexible, e.g. films
- B29C 48/28: Storing of extruded material, e.g. by winding up or stacking
- B29C 48/305: having a wide opening, e.g. for forming sheets
- B29C 48/40: using two or more parallel screws {or at least two parallel non-intermeshing screws}, e.g. twin screw extruders
- C08L 75/04: Polyurethanes
- B29B 7/10: rotary
- B29B 7/48: with intermeshing devices, e.g. screws
- B29B 7/726: {Measuring properties of mixture, e.g. temperature or density (B29B7/724 takes precedence)}
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2509/08: Glass
- B29K 2995/0016: Non-flammable or resistant to heat
- B29L 2031/732: {Floor coverings (piles carpets B29L2031/7652; for vehicles B29L2031/3017)}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- 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
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- 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)
- 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
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

Included is a homogeneous sheet, which excludes polyvinylchloride. The sheet includes a polyurethane, a synthetic rubber blend, and a filler. The synthetic rubber blend may include a pre-mix of a synthetic rubber and white oil.

## Claims

### Claim 1

A method for preparing a homogeneous sheet or film comprising:
(a) providing sheet components including a thermoplastic polyurethane, a synthetic rubber blend, and a filler;
(b) combining the sheet components with a first pigment;
(c) extruding said combined sheet components of step (b) through a die or calendar to form a first colored film;
(d) with the first colored film cooled, granulating the cooled first colored film into first single-colored chips;
(e) combining the sheet components with a second pigment;
(f) extruding said combined sheet components of step (e) through a die or calendar to form a second colored film;
(g) with the second colored film cooled, granulating the cooled second colored film into second single-colored chips;
(h) blending at least a portion of the first single-colored chips with at least a portion of the second single-colored chips, and optionally other components, to form a uniform mixture;
(i) heating the mixture;
(j) consolidating the heated mixture to form the homogeneous sheet or film.

### Claim 2 (depends on 1)

The method of claim 1, wherein said homogeneous sheet or film is sheet flooring having a thickness of about 0.1 mm to about to 4.0 mm.

### Claim 3 (depends on 1)

The method of claim 1, wherein said homogeneous sheet or film is sheet flooring having a thickness of about 0.1 mm to about 2.0 mm.

### Claim 4 (depends on 1)

The method of claim 1, wherein said homogeneous sheet or film is combined with a decorative layer.

### Claim 5

The method of 1, wherein said consolidating includes pressing followed by annealing and cooling.

### Claim 6 (depends on 5)

The method of claim 5, wherein a coating is added after consolidation and before annealing.

### Claim 7 (depends on 1)

The method of claim 1, wherein said thermoplastic polyurethane is derived from a polymer selected from a polyester, a polyether, and combinations thereof.

### Claim 8 (depends on 7)

The method of claim 7, wherein said thermoplastic polyurethane is present in an amount of about 20% to about 60% by weight of the sheet components.

### Claim 9 (depends on 1)

The method of claim 1, wherein said synthetic rubber blend comprises a block copolymer or terpolymer derived from monomers including a styrene monomer.

### Claim 10 (depends on 9)

The method of claim 9, wherein said synthetic rubber blend is a pre-blend prepared from a synthetic rubber and white oil.

### Claim 11 (depends on 1)

The method of claim 1, wherein said filler is selected from the group consisting of limestone, talc, mica, wollastonite, kaolinite, mica, glass fiber, glass bead, and combinations thereof.

### Claim 12 (depends on 11)

The method of claim 11, wherein said filler is present in an amount of about 20% to about 60% by weight of the sheet components.

### Claim 13 (depends on 1)

The method of claim 1, wherein said sheet components further comprise at least one functional additive selected from the group consisting of flame retardants, antioxidants, heat stabilizers, light stabilizers, fluorescent or phosphorescent additive, luminous additives, process aids, pigment and combinations thereof.

### Claim 14 (depends on 13)

The method of claim 13, wherein said flame retardants include at least one flame retardant selected from group consisting of solid flame retardant, liquid flame retardant, and combinations thereof.

### Claim 15 (depends on 1)

The method of claim 1, wherein the first and second pigments are different.

### Claim 16 (depends on 15)

The method of claim 15, wherein the first and second pigments are different in one or both of: color and concentration.