Glueless dustless composite flooring material system
Assigneei4F Licensing NV
InventorJohn B. Troendle
Life of this patent
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Abstract
A glueless dustless composite flooring material system providing PVC-based flooring having waterproof layers providing different qualities of hardness, wear-resistance, sound deadening, and decorative patterns, avoiding the use of moisture-susceptible compressed dust filler, with layers fused together, avoiding the manufacturing complexity and delamination risks of using glue or adhesive, with a quickly-cured, UV-cured top coating providing long-lasting high performance and shortening and simplifying the manufacturing, which can be done in a sheet-form, essentially continuous-run manner, with an ability to quickly and simply change the optional design printing and texturing produced, and having an optional underlayment layer.
Claims28
A composite flooring segment having a nominal top and bottom direction, comprising:
- (i) a flooring base layer comprising a mixture of PVC resin and calcium carbonate, wherein said flooring base layer is free of glue;
- (ii) a flooring face layer comprising a decorative face sublayer and a wearing face sublayer applied on top of said decorative face sublayer;
- wherein said wearing face sublayer is fused onto the decorative face sublayer by hot-melt overlaying,
- wherein said flooring face layer is fused without adhesives onto a top face of said flooring base layer by hot-melt overlaying,
- wherein said decorative face sublayer has a printed pattern or image;
- wherein said flooring face layer has a decoratively textured surface, and wherein said decoratively textured surface defines a textured top surface of said flooring segment;
- and
- (iii) a flooring coating layer, applied on top of said flooring face layer.
Dependencies are inferred from the claim text.