# US 12,109,787 B2 · Rigid multilayer decorative surface covering

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- Number: US 12,109,787 B2
- Document ID: US12109787B2
- Status: Granted
- Kind: B2
- Application number: 18/178,947
- Filed: 2023-03-06
- Published: 2023-10-12
- Granted: 2024-10-08
- Earliest claimed: 2022-04-12
- Assignees: Tarkett GDL
- Applicants: Tarkett GDL
- Inventors: Mathieu Coquelle; Nicolas Boquillon; Diego Gourdin
- Web page: https://patentgrep.com/patent/US12109787B2

## CPC

- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder
- B32B 27/065: {of foam}
- B32B 27/22: using plasticisers
- B32B 27/40: comprising polyurethanes
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- E04F 13/0866: {composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence)}
- E04F 13/18: of organic plastics with or without reinforcements or filling materials (of plastic-bound fibres or chips E04F13/16 ){or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles (E04F13/0864 takes precedence)}
- B32B 2250/24: All layers being polymeric
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material
- B32B 2305/70: Scrap or recycled material
- B32B 2307/412: Transparent
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/558: Impact strength, toughness
- B32B 2307/732: Dimensional properties
- B32B 2451/00: Decorative or ornamental articles
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2607/00: Walls, panels
- B32B 2607/02: Wall papers, wall coverings
- B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers
- 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: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}

## Abstract

A rigid multilayer decorative surface covering is proposed. The surface covering has a thickness and comprises a sandwiched reinforcement composite layer comprising a thermoplastic polymer matrix having a top and a bottom surface, the sandwiched reinforcement composite layer comprising reinforcement layers on the top and bottom surfaces. The sandwiched reinforcement composite layer has a thickness comprised in the range from 25% to 85% of the thickness of the rigid decorative surface covering. A method for manufacturing the rigid multilayer decorative surface covering is also disclosed.

## Claims

### Claim 1

A rigid multilayer decorative surface covering having a thickness, the surface covering comprising a sandwiched reinforcement composite layer comprising a thermoplastic polymer matrix having a top and a bottom surface, the sandwiched reinforcement composite layer comprising reinforcement layers directly on the top and bottom surfaces, the sandwiched reinforcement composite layer having a thickness comprised in the range from 25% to 85% of the thickness of the rigid multilayer decorative surface covering, wherein the reinforcement layers comprise a woven, fiber material non-woven fiber material, glass or polypropylene, the thermoplastic matrix further comprising two additional reinforcement layers, the two additional reinforcement layers being vertically located at +/−15% relative to the vertical center of the sandwiched reinforcement composite layer.

### Claim 2 (depends on 1)

The decorative surface covering as claimed in claim 1, wherein the sandwiched reinforcement composite layer has a thickness comprised in the range from 35% to 75% of the thickness of the rigid decorative surface covering.

### Claim 3 (depends on 1)

The decorative surface covering as claimed in claim 1, wherein each of the reinforcement layers are selected from the group consisting of veils of glass fibers, nets of glass fibers, and fleeces of glass fibers.

### Claim 4 (depends on 1)

The decorative surface covering as claimed in claim 1, wherein the thermoplastic polymer matrix comprises polyvinyl chloride, a copolymer comprising vinyl chloride and vinyl acetate, a copolymer comprising vinyl chloride and butyl acrylate or polyvinyl butyral.

### Claim 5 (depends on 4)

The decorative surface covering as claimed in claim 4, wherein the polyvinyl chloride, the copolymer comprising vinyl chloride and vinyl acetate, the copolymer comprising vinyl chloride and butyl acrylate or the polyvinyl butyral is in the form of agglomerated granules.

### Claim 6 (depends on 1)

The decorative surface covering as claimed in claim 1, wherein the thermoplastic polymer matrix comprises recycled polyvinyl chloride.

### Claim 7 (depends on 1)

The decorative surface covering as claimed in claim 1, further comprising a decorative print on a top surface of the sandwiched reinforcement composite layer.

### Claim 8 (depends on 1)

The decorative surface covering as claimed in claim 1, further comprising a wear layer.

### Claim 9 (depends on 8)

The decorative surface covering as claimed in claim 8, further comprising a topcoat.

### Claim 10 (depends on 1)

The decorative surface covering as claimed in claim 1, further comprising a protective layer on the bottom surface of the sandwiched reinforcement composite layer.

### Claim 11 (depends on 1)

The decorative surface covering as claimed in claim 1, further comprising a foamed layer for contacting a surface to be covered by the decorative surface covering.

### Claim 12 (depends on 1)

The decorative surface covering as claimed in claim 1, wherein the decorative surface covering is a rigid multilayer decorative wall or floor covering.

### Claim 13 (depends on 1)

A method for manufacturing a rigid multilayer decorative surface covering as claimed in claim 1, comprising:
a) providing a reinforcement layer;
b) scattering thermoplastic resin on the reinforcement layer of step a);
c) providing two additional reinforcement layers on the scattered thermoplastic resin of step b);
d) scattering thermoplastic resin on a top surface of the two additional reinforcement layers of step c);
e) providing a second reinforcement layer on the scattered thermoplastic resin of step d) so as to form a stack of layers; and
f) heating and pressing the stack of layers so as to form the sandwiched reinforcement composite layer, wherein the thermoplastic resin forms a thermoplastic polymer matrix.

### Claim 14 (depends on 13)

The method as claimed in claim 13, wherein the thermoplastic resin is mixed with plasticizer, the plasticizer not exceeding 15% by weight of the surface covering.

### Claim 15 (depends on 13)

The method as claimed in claim 13, wherein no plasticizer is mixed with the thermoplastic resin.