US 8,021,741 B2Granted

Thermoplastic planks and methods for making the same

AssigneeMannington Mills, Inc.

InventorsHao A. Chen, Richard Judd

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Abstract

A thermoplastic laminate plank is described wherein the thermoplastic laminate plank comprises a core, a print layer, and optionally an overlay. The core comprises at least one thermoplastic material and has a top surface and bottom surface wherein a print layer is affixed to the top surface of the core and an overlay layer is affixed to the top surface of the print layer. Optionally, an underlay layer can be located and affixed between the bottom surface of the print layer and the top surface of the core. In addition, a method of making the thermoplastic laminate plank is further described which involves extruding at least one thermoplastic material into the shape of the core and affixing a laminate on the core, wherein the laminate comprises an overlay affixed to the top surface of the print layer and optionally an underlay layer affixed to the bottom surface of the print layer.

Claims41

Dependent claims

A thermoplastic laminate plank comprising:

a core comprising at least one flexible thermoplastic material, wherein said core has a top surface and a bottom surface, and opposing sides;
a print layer optionally with an underlay layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprising a printed design;
and
a protective layer affixed to said top surface of said print layer, wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture,
wherein said core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm, and wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, wherein said at least one flexible thermoplastic material is flexible polyvinyl chloride, wherein said flexible thermoplastic material has a molecular weight as reflected by an inherent viscosity of from about 0.88 to about 1.0 inherent viscosity, and
wherein said print layer is a thermoplastic film with a printed design, and
wherein said protective layer comprises a polyurethane coating with or without wear resistant particles in the polyurethane coating, and
wherein said core further comprises at least one plasticizer and filler, wherein said plasticizer is present in an amount of less than about 20% by weight of said core.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 12/825,447Filed 29 Jun 2010 · continuation
Priority: 14 Dec 1999
Published: US 2010/0260962 A114 Oct 2010
Granted: 20 Sep 2011
Term ends: Not estimatedThe source records don’t support an estimate.

Classification75 codes

B32B 27/10
As the main or only constituent of a layer, which is next to another layer of the same or of a different material: of paper or cardboard
B29C 48/001
Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor: combinations…
B29C 48/07
Characterised by the shape of the extruded material at extrusion: flat, e.g. panels
B29C 48/11
Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels: comprising two or more partially or fully…

Family

Application09/460,928Parent of this division · filed 14 Dec 1999
Application10/104,383Parent of this continuation · filed 22 Mar 2002
Application11/788,421Parent of this continuation · filed 20 Apr 2007
Application12/196,488Parent of this continuation · filed 22 Aug 2008
US 2010/0260962 A1Pre-grant publication · published 14 Oct 2010
US 7,763,345 B2Parent of this continuation
US 7,419,717 B2Parent of this continuation
US 7,211,310 B2Parent of this continuation
US 6,617,009 B1Parent of this division
Application10/104,383Parent of this division
US 2002/0142135 A1Published application
US 2007/0196624 A1Published application
US 2008/0311355 A1Published application
US 8,021,741 B2This patent

From the US filing history. Foreign family members aren’t listed.