Glueless dustless composite flooring material system
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.
1. 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.
2. The composite flooring segment of claim 1 , wherein said flooring coating layer comprises a UV-curable resin.
3. The composite flooring segment of claim 1 , wherein said wearing face sublayer comprises a wear-resistant polymer.
4. The composite flooring segment of claim 1 , further comprising (v) an underlayment layer positioned underneath said flooring base layer and affixed to a bottom surface of said flooring base layer.
5. The composite flooring segment of claim 1 , wherein said decorative face sublayer comprises a colored PVC based film bearing a printed decorative pattern or image.
6. The composite flooring segment of claim 1 , wherein said decorative face sublayer comprises a digitally printed decorative pattern or image.
7. The composite flooring segment of claim 1 , wherein said textured surface is complementary to a pattern or image of said decorative face sublayer.
8. The composite flooring segment of claim 1 , wherein said wearing face sublayer is transparent.
9. The composite flooring segment of claim 1 , wherein said wearing face sublayer further comprises a PVC wear-resistant polymer film.
10. The composite flooring segment of claim 1 , wherein said flooring coating layer is transparent.
11. The composite flooring segment of claim 1 , wherein said flooring coating layer further comprises a gritty particulate material.
12. The composite flooring segment of claim 1 , wherein said flooring coating layer further comprises aluminumoxide.
13. The composite flooring segment of claim 1 , wherein said flooring coating layer provides a matte finish.
14. The composite flooring segment of claim 1 , wherein said flooring base layer is free of compressed cellulose.
15. The composite flooring segment of claim 1 , wherein said flooring base layer further comprises a plurality of co-extruded sublayers each having different mixtures of PVC resins and other materials.
16. The composite flooring segment of claim 1 , wherein said flooring base layer comprises a foam layer.
17. The composite flooring segment of claim 1 , wherein said flooring base layer further comprises by weight PVC between 18.13% and 64.71% inclusive, and calcium carbonate between 32.35% and 72.53% inclusive.
18. The composite flooring segment of claim 1 , wherein said decoratively textured surface is at least partially complementing said pattern or image of said decorative face.
19. The composite flooring segment of claim 1 , wherein said flooring coating layer comprises a film material.
20. The composite flooring segment of claim 1 , wherein said decorative face sublayer comprises a white base layer bearing a printed decorative pattern or image.
21. The composite flooring segment of claim 1 , wherein a plurality of edges of the flooring segment is provided with installation profiles for installation purposes.
22. The composite flooring segment of claim 1 , wherein a plurality of edges of the flooring segment is provided with coupling profiles for locking with an adjacent composite flooring segment.
23. The composite flooring segment of claim 1 , where the flooring base layer is a waterproof layer.
24. The composite flooring segments of claim 1 , where said flooring face layer is a waterproof layer.
25. The composite flooring segment of claim 1 , comprising at least four sides, at least two of which comprise bevels.
26. The composite flooring material segment of claim 25 , wherein the bevels are painted with colors, wherein the colors imitate wood, tiles, textile, marble, grout, or combinations thereof.
27. The composite flooring material segment of claim 25 , wherein the bevels define a shape, wherein the shape comprises straight lines, angled lines, a square, rounded arcs, or combinations thereof.
28. The composite flooring material segment of claim 1 , wherein the decoratively textured surface is in register with the printed pattern or image.