Flooring products and methods of making the same
A plank is described wherein the plank comprises a core, and optionally, a print layer, and optionally an overlay. The core includes from about 30 wt % to about 95 wt % at least one polymeric material, by weight of the core, and from about 5 wt % to about 70 wt % of least one natural fiber or flour, by weight of the core, wherein the core includes a top surface and a bottom surface, and opposing sides, wherein said plank is substantially moisture resistant, having a swelling property of from about 0.5% to about 5% by NALFA Thickness Test Section 3.2 LF 01-2003 standard, and wherein said plank includes a bow of from about 0.5% to about 4%. In addition, a method of making the plank is further described.
1 . A plank comprising:
a core comprising from about 30 wt % to about 95 wt % of at least one polymeric material, by weight of said core, and from about 5 wt % to about 80 wt % of at least one natural fiber or flour, by weight of said core, wherein said core has a top surface and a bottom surface, and opposing sides, wherein said plank is substantially moisture resistant, having a swelling property of from 0.5% to about 5%, by NALFA Thickness Test Section 3.2 LF 01-2003 standard, and wherein said plank includes a downward bow or dome of from about 0.5% to about 4%.
2 . The plank of claim 1 , wherein said plank has a density of from about 60 lbs/ft 3 to about 85 lbs/ft 3 .
3 . The plank of claim 1 , wherein said plank has a glass transition temperature of about −50° C. or higher.
4 . The plank of claim 3 , wherein said glass transition temperature is from about −45° C. to about 105° C.
5 . The plank of claim 1 , wherein said core has a thickness of from about 5 mm to about 20 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm.
6 . The plank of claim 1 , wherein said core has a plurality of cavities.
7 . The plank of claim 1 , wherein two sides of said core are tapered or have beveled edges, wherein said sides are opposite to each other.
8 . The plank of claim 1 , wherein said polymeric material comprises a melt index of from about 0.4 to about 20 grams/10 minutes.
9 . The plank of claim 1 , wherein said polymeric material includes a melt index of from about 0.8 to about 3 grams/10 minutes.
10 . The plank of claim 1 , wherein said polymeric material comprises a polyolefin group.
11 . The plank of claim 10 , wherein said polyolefin group comprises a polyethylene.
12 . The plank of claim 1 , wherein said polymeric material comprises a polypropylene, a polyvinyl chloride, a copolymer of PVC, or a combination thereof.
13 . The plank of claim 1 , wherein said polymeric material comprises at least one thermoplastic material, at least one plasticizer, and at least one coupling agent.
14 . The plank of claim 13 , wherein said plasticizer is present in an amount of less than about 20% by weight of said core.
15 . The plank of claim 1 , wherein said natural fiber or flour includes a particle size of from about 50 mil or less.
16 . The plank of claim 1 , where in said natural fiber or flour has a particle size of from about 30 mil or less.
17 . The plank of claim 1 , wherein said natural fiber or flour includes from about 10 wt % to about 40 wt % of a fiber or flour having a size of from about 20 mil to about 30 mil; from about 10 wt % to about 30 wt % of a fiber or flour having a size of from about 15 mil to about 20 mil; from about 10 wt % to about 30 wt % of a fiber or flour having a size of from about 5 mil to about 15 mil, and from about 0 wt % to about 20 wt % of a fiber or flour having a size of about 5 mil or less.
18 . The plank of claim 1 , wherein said natural fiber or flour comprises a moisture content of about 1 wt % or less.
19 . The plank of claim 1 , wherein said natural fiber or flour comprises wood, a cellulose source other than wood, or a combination thereof.
20 . The plank of claim 1 , wherein said plank has a swelling property of from 0.5% to about 3% by NALFA Thickness Test Section 3.2 LF 01-2003 standard.
21 . The plank of claim 1 , wherein said plank comprises a bow of from about 0.5 inch to about 3.5 inches.
22 . The plank of claim 1 further comprising at least one lubricant.
23 . The plank of claim 22 , wherein said lubricant in present in an amount of from about 1% to about 5% or more, by weight of said core.
24 . The plank of claim 22 , wherein said lubricant comprises a polyester lubricant.
25 . The plank of claim 22 , wherein said lubricant comprises a polyolefin wax, an amide wax, a montanic acid ester, a metallic stearate, a calcium stearate, a zinc stearate, a metal salt of a long chain carboxylic acid, a paraffin, or any combination thereof.
26 . The plank of claim 1 further comprising at least one compatibilizer or coupling agent.
27 . The plank of claim 26 , wherein said compatibilizer or coupling agent is present in an amount of from about 0.5 wt % to about 5 wt %, by weight of said core.
28 . The plank of claim 26 , wherein said compatibilizer or coupling agent comprises a maleic anhydride.
29 . The plank of claim 1 , further comprising a laminate, wood veneer, vulcanized cellulose layer, or a combination thereof on said top surface.
30 . The plank of claim 1 , further comprising an underlay layer located and affixed between bottom surfaces of a top layer and said top surface of said core.
31 . The plank of claim 30 , wherein said underlay comprises an aminoplast resin impregnated paper.
32 . The plank of claim 30 , wherein said underlay comprises Kraft paper impregnated with an aminoplast resin.
33 . The plank of claim 30 , wherein an adhesive is present between said cores and said underlay layer in order to affix said underlay layer to said core.
34 . The plank of claim 30 , further comprising a printed design.
35 . The plank of claim 30 , further comprising a protective layer affixed to said top surface of said top layer.
36 . The plank of claim 35 , wherein said protective layer comprises an aminoplast resin impregnated overlay paper and aluminum oxide imbedded on the top surface of said paper.
37 . The plank of claim 35 , wherein said protective layer comprises an aminoplast resin impregnated overlay paper.
38 . The plank of claim 30 , wherein said plank includes a bow of from about 2.5 inches to about 3.2 inches.
39 . The plank of claim 30 , wherein said top layer comprises a decorative element.
40 . The plank of claim 30 , wherein said top layer is embossed with a design.
41 . The plank of claim 1 , wherein said bottom surface of said core is thermally treated.
42 . The plank of claim 1 , further comprising at least one design layer.
43 . The plank of claim 42 , wherein said design layer has the design of natural wood, stone, ceramic, brick, or tile.
44 . The plank of claim 42 , wherein said plank further comprises a layer that has texture or said top surface of core has a textured surface or both.
45 . The plank of claim 44 , wherein said design on said design layer and said texture are in register.
46 . The plank of claim 44 , wherein said texture simulates the texture present in natural wood, stone, ceramic, brick, or tile.
47 . A floor comprising a plurality of the planks of claim 1 joined together.
48 . The floor of claim 47 , wherein the planks are joined together by a mechanical locking system.
49 . The floor of claim 47 , wherein the planks are joined together by a bonding agent.
50 . The floor of claim 47 , wherein the planks are joined together by a tongue and grove connection.
51 . The floor of claim 47 , wherein the planks are joined together by a grove and spline system.
52 . The floor of claim 47 , wherein said floor is a floating floor.