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US 2024/0417982 A1Published application
Engineered waterproof plastic composite flooring and wall covering planks
AssigneeShaw Industries Group, Inc.
InventorsPiet V. Dossche, Philippe Erramuzpe
Life of this patent
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Abstract
Waterproof engineered floor and wall planks have a veneer layer bonded with a plastic composite core, and an underlayer, preferably an underlayer of cork.
Claims24
1-20. (canceled)
An engineered waterproof plank comprising:
- an extruded waterproof core comprising a composite that includes cork and less than 10% of additives selected from the group consisting of anti-oxidation agents, stabilizers, colorants, anti-fungus agents, coupling agents, reinforcing agents, and lubricants;
- a wear layer adhered to a top surface of the waterproof core;
- a waterproof adhesive layer bonding the wear layer to the top surface of the waterproof core;
- and
- a first edge with a groove extending laterally into the waterproof core and a second opposite edge with a lateral protrusion from the waterproof core, wherein the groove and protrusion have profiles shaped to form a click-lock edge fastening system.
2 more elements
An engineered waterproof plank comprising:
- (a) a veneer layer comprising one or more of cork, bamboo, or wood, said veneer layer encapsulated in resin, and said veneer layer adhered to a top surface of a waterproof core;
- (b) an underlayer comprising one or more of cork, rubber, foam, or paper, said underlayer adhered to a bottom surface of the waterproof core;
- (c) the waterproof core comprising:
- (i) at least about 55% of dust selected from the group consisting of wood, bamboo and cork;
- (ii) at least about 20% of plastic selected from the group consisting of high-density polyethylene and polyvinyl chloride;
- and
- (iii) about 10% or less of additives selected from the group consisting of anti-UV agents, anti-oxidation agents, stabilizers, colorants, anti-fungal agents, coupling agents, reinforcing agents, and lubricants;
- (d) wherein a groove extends laterally along a first edge of the waterproof core and a lateral protrusion extends from an opposite second edge of the waterproof core, the groove and protrusion comprising a click-lock edge fastening system.
5 more elements
An engineered waterproof plank comprising:
- (a) a waterproof plastic composite core having a top surface and a bottom surface;
- (b) a first waterproof bonding layer joining a veneer layer to the top surface of the waterproof core;
- and
- (c) a second waterproof bonding layer joining an underlayer to the bottom surface of the waterproof core,
- (d) wherein a bottom surface of the underlayer is attached to at least one of a subfloor or a wall by an adhesive.
2 more elements
An engineered plank comprising:
- a rigid inert core that is at least one of waterproof or water-resistant,
- wherein said rigid inert core comprises a thermoplastic polymer and a filler, and
- wherein said filler comprises calcium carbonate;
- a veneer layer disposed on a top surface of the rigid inert core,
- wherein the veneer layer is selected from a group consisting of wood, cork, bamboo, tile, stone, rubber, decorative plastic, linoleum and decorative vinyl, and
- wherein the veneer layer is bonded to the top surface of the rigid inert core via a waterproof bonding;
- a protective cover layer disposed above the veneer layer, wherein the protective cover layer comprises one of a melamine based layer, an aluminum oxide based layer, or a polyurethane based layer;
- and
- wherein the engineered plank further comprises a locking mechanism to interlock one engineered plank to another engineered plank.
6 more elements
Dependencies are inferred from the claim text.