LVT Formulation for Achieving Drum Tack While Maintaining Good Cut Smoothness

1 . A floor panel comprising:

a base layer comprising:

a binder, and

a filler having a particle size distribution such that about 6 wt, % to 80 wt. % by weight of the filler passing through a 200 mesh screen.

2 . The floor panel according to claim 1 wherein the particle size distribution is such that 100 wt. % of the filler passes through a 40 mesh screen.

3 . The floor panel according to claim 2 wherein the particle size distribution is such that about 96 wt. % to about 100 wt. % of the filler passes through a 50 mesh screen.

4 . The floor panel according to any one of claims 1 to 3 wherein the particle size distribution is such that greater than about 30 wt. % of the filler passes through a 100 mesh screen.

5 . The floor panel according to claim 4 wherein the particle size distribution is such that less than about 95 wt. % of the filler passes through a 100 mesh screen.

6 . The floor panel according to any one of claims 1 to 3 wherein the particle size distribution is such that less than about 80 wt. % of the filler passing through a 100 mesh screen.

7 . The floor panel according to any one of claims 1 to 6 wherein the particle size distribution is such that less than about 25 wt. % of the filler passes through a 325 mesh screen.

8 . The floor panel according to claim 1 wherein the particle size distribution is such that about 30 wt. % to about 90 wt. % of the filler passes through a 100 mesh screen, and less than 20 wt. % by weight of the filler passes through a 325 mesh screen.

9 . The floor panel according to any one of claims 1 to 9 wherein binder comprises a vinyl polymer.

10 . The floor panel according to any one of claims 1 to 10 wherein the filler is selected from a group consisting of calcium carbonate, magnesium carbonate, talc, barytes, silica, and combinations thereof.

11 . The floor panel according to any one of claims 1 to 11 wherein the base layer further comprises a plasticizer.

12 . The floor panel according to claim 11 wherein the base layer comprises:

the binder in an amount of about 20 wt. % to about 40 wt. % of the base layer;

the filler in an amount of about 30 wt % to about 80 wt. % of the base layer; and

the plasticizer, wherein the plasticizer is present in a weight ratio with the binder ranging from about 1:2.5 to about 1:4.

13 . The floor panel according to any one of claims 1 to 12 further comprising a print layer on an upper surface of the base layer.

14 . The floor panel according to any one of claims 1 to 13 wherein the floor panel comprises an uppermost exposed surface comprising embossed features.

15 . The floor panel according to claim 14 further comprising a wear layer atop the print layer.

16 . A method of forming a floor panel comprising:

a) forming a base sheet from a binder and a filler having a particle size distribution such that about 6 wt. % to about 80 wt. % of the filler passes through a 200 mesh screen;

b) bringing the base sheet into contact with an outer surface of a rotating drum, the base sheet adhering to the rotating drum, the outer surface of the rotating drum having an average surface roughness greater than 8 microinches; and

c) feeding the base sheet through one or more process stations while the base sheet remains adhered to the outer surface of the rotating drum, thereby forming a laminate sheet.

17 . The method according to claim 16 , wherein the outer surface of the rotating drum has an average surface roughness ranging from 25 microinches to 75 microinches.

18 . The method according to any one of claims 16 to 17 , wherein the base sheet passes through one or more process stations at a feed rate ranging from 10 meters per minute to 35 meters per minute.

19 . The method according to any one of claims 16 to 18 , wherein the drum is operated at a temperature ranging from 80° C. to 125° C.

20 . The method according to any one of claims 16 to 19 , wherein the drum has a diameter ranging from about 30 cm to about 125 cm.

21 . The method according to any one of claims 16 to 19 , wherein the drum has a diameter ranging from about 122 cm to about 305 cm.

22 . The method according to any one of claims 16 to 21 , wherein the particle size distribution is such that about 96 wt. % to about 100 wt. % of the filler passes through a 50 mesh screen.

23 . The method according to any one of claims 16 to 22 , wherein the particle size distribution is such that greater than about 30 wt. % of the filler passing through a 100 mesh screen.

24 . The method according to any one of claims 16 to 23 , wherein the particle size distribution is such that about 30 wt. % to 90 wt. % of the filler passing through a 100 mesh screen, and less than about 25 wt. % of the filler passing through a 325 mesh screen

25 . The method according to any one of claims 16 to 24 wherein binder comprises a vinyl polymer and the filler is selected from a group consisting of calcium carbonate, magnesium carbonate, talc, barytes, silica, and combinations thereof.

26 . The method according to anyone of claims 16 to 25 , wherein step c) comprises:

c-1) feeding the base sheet through a print layer application station in which the base sheet and a print sheet are passed between the drum and a print roller such that the print sheet is laminated to the base sheet, the base sheet remaining adhered to the outer surface of the rotating drum during lamination of the print sheet to the base sheet.

27 . The method according to claim 26 , wherein the drum has a first diameter and the print roller has a second diameter, the first diameter being greater than the second diameter.

28 . The method according to anyone of claims 16 to 25 , wherein step c) comprises:

c-2) feeding the base sheet through a wear layer application station in which the base sheet and a wear sheet are passed between the drum and a wear roller such that the wear sheet is laminated to the base sheet, the base sheet remaining adhered to the outer surface of the rotating drum during lamination of the wear sheet to the base sheet.

29 . The method according to claim 28 , wherein the drum has a first diameter and the wear roller has a third diameter, the first diameter being greater than the third diameter.

30 . The method according to anyone of claims 16 to 25 , wherein step c) comprises:

c-3) feeding the base sheet through an embossing station in which the lamination sheet is passed between the drum and an embossing roller, the base sheet portion of the lamination sheet remaining adhered to the outer surface of the rotating drum during embossing.

31 . The method according to claim 30 , wherein the drum has a first diameter and the embossing roller has a fourth diameter, the first diameter being greater than the fourth diameter.

32 . The method according to anyone of claims 32 to 31 , wherein step c-3) further comprises:

laminating a top-film sheet at the embossing station in which a top-film sheet and the base layer are passed between the drum and a embossing roller such that the top-film sheet is laminated to the base sheet, the base sheet remaining adhered to the outer surface of the rotating drum during lamination of the top-film sheet to the base sheet.

33 . The method according to any one of claims 16 to 32 wherein steps a) through c) are a continuous roll forming process

34 . The method according to anyone of claims 16 to 25 , wherein step c) comprises:

feeding the base sheet through a print layer application station in which the base sheet and a print sheet are passed between the drum and a print roller such that the print sheet is laminated to the base sheet to form a base-print sheet laminate, the base sheet remaining adhered to the outer surface of the rotating drum during lamination of the print sheet to the base sheet;

feeding the base-print sheet laminate through a wear layer application station in which the base-print sheet laminate and a wear sheet are passed between the drum and a wear roller such that the wear sheet is laminated to the base-print sheet laminate to form a base-print-wear sheet laminate, the base sheet of the base-print sheet laminate remaining adhered to the outer surface of the rotating drum during lamination of the wear sheet to the base-print sheet laminate;

feeding the base-print-wear sheet laminate through an embossing station in which the base-print-wear sheet laminate and a top-film sheet are passed between the drum and an embossing roller such that the top-film sheet is laminated to the base-print-wear sheet laminate to form a base-print-wear-top-film sheet laminate while having an embossing pattern imprinted by the embossing roller, and base sheet of the base-print-wear sheet laminate remaining adhered to the outer surface of the rotating drum during embossing and/or lamination of the top-film sheet to the base-print-wear sheet laminate.

35 . The method according to any one of claims 16 to 34 further comprising:

d) removing the laminate sheet from the drum;

e) feeding the laminate sheet into a cutting station, thereby cutting laminate sheet into a plurality of floor panels.