METHOD FOR PRODUCTION OF A DUST-FREE AND GLUE-FREE COMPOSITE FLOORING MATERIAL SYSTEM

Abstract

A method for producing a dust-free and glue-free composite flooring material system that provides a PVC-based floor having waterproof layers that provide different qualities of hardness, wear resistance, soundproofing and decorative patterns, avoiding the use of moisture-susceptible compressed cellulose-based filler, with layers fused together, avoiding the manufacturing complexity and risks of delamination from the use of glue or adhesive, with a fast-curing and UV-cured top coating that provides high-performance durability and shortens and simplifies manufacturing, which can be made in sheet form, essentially continuously, with the ability to quickly and easily change the optional design printing and texture produced, and which has an optional underlayment layer.

Description

METHOD FOR PRODUCING A DUST-FREE AND GLUE-FREE COMPOSITE FLOORING MATERIAL SYSTEM Descriptive report Reference to related applications This application claims priority over application No. 16 / 432.106, filed on June 5, 2019, entitled "Method of Producing a Glueless Dustless Composite Flooring Material System," the full disclosure of which is incorporated herein by reference and whose priority is hereby claimed. Background of the Invention This invention provides a method for producing a dust-free and glue-free PVC-based composite flooring material system that is efficiently manufactured and produces a durable, high-performance floor. Existing flooring materials that use compressed sawdust or powder as their core material are susceptible to damage and premature failure from water or other liquids, especially in humid environments and applications requiring frequent cleaning. However, the compressed powder core provides the flooring material with certain desirable characteristics, such as sound insulation. Eliminating the compressed powder from the flooring composition requires a novel approach to recovering these characteristics through the use of different materials or manufacturing processes. Existing laminate flooring products that use glue or adhesive to bond the layers are susceptible to delamination and premature failure, especially in humid environments. The handling, application, and assembly or curing of adhesives add complexity to the flooring manufacturing process, making this stage a potential bottleneck that hinders efficient continuous or long-run production. Applying a topcoat to flooring material is a good way to improve its appearance and wear resistance. However, when the flooring material contains PVC, achieving proper adhesion of a topcoat during the manufacturing process presents challenges, and there are additional potential issues with premature delamination after installation. To achieve good adhesion during manufacturing, coatings are currently used that require extended curing times or complex handling. Polyurethane undergoes oxidative curing, which is likely to take eight to ten hours. A two-component epoxy is likely to take at least thirty minutes to cure, which is still a long time and another potential bottleneck preventing continuous production. Furthermore, two-component epoxies require additional mixing and handling during the manufacturing process. Surface designs and textures are typically printed and pressed into the paving material, often imitating wood, stone, or tile. Current methods of applying these decorative patterns and textures are primarily limited to short, frequently repeating patterns printed using a roller or plate of a finite size. When more than one color, tint, shade, or hue is to be applied, registration problems often arise. These limitations preclude any ability to change production from one decorative pattern to another. Once the production of a particular decorative pattern is calibrated and registered, there is a certain reluctance to make changes. When flooring manufacturers have to address these problems, the price is likely to increase or profits to decrease. If the problems are not resolved, the flooring material is likely to fail prematurely. Therefore, flooring material is needed that is free of any water-based products, such as inks or dyes, adhesives, and compressed cellulose material, such as sawdust or dust, while still possessing the desired qualities. A manufacturing method that is more efficient, more economical, offers more variety in decorative patterns, is faster, and produces a more durable, high-performance flooring material is also currently needed. U.S. Publication No. Q2011 / 0030300 for Floor and Tile with Padding, published on February 10, 2011, by David C. Liu, discloses a flexible flooring panel with a pad attached to the underside of the panel. The pad partially covers the underside of the panel and extends beyond it. The underside of the pad is coated with a re-adhesive layer, and the panel has a male locking mechanism at one end and a female locking mechanism at the other. A flooring panel is mated to an adjacent panel by pressing down the female locking mechanism of the first panel onto the male locking mechanism of the second panel. The underside of the first panel that is not covered by the pad is placed in contact with the pad of the second panel that extends beyond it.Liu's flooring was developed to meet the need for a wood floor without the installation problems associated with both glued and floating methods. The wood flooring was designed for easy installation without cumbersome glue, delamination, hollow areas, or rapid water damage. U.S. Publication No. s2009 / 0223162 for Connecting System for Surface Coverings, published September 10, 2009, by Hao A. Chen et al., discloses a sheet having opposite first and second ends extending along a width of the sheet, opposite first and second longitudinal sides extending along a length of the sheet, and opposite top and bottom surfaces. The sheet may have a tongue edge at the first end and a groove edge at the second end. The tongue edge can be detachably locked into the groove edge of an identical adjacent sheet. Surface covering systems having a plurality of sheets connected together are also provided. In particular, a preferred embodiment of the floor sheet comprises (1) a top surface; (2) a bottom surface; (3) a first longitudinal side;(4) a second longitudinal side opposite the first longitudinal side; (5) a first end extending across the width of the floor plate and comprising a tongue edge; and (6) a second end opposite the first end, extending across the width of the floor plate and comprising a groove edge. The tongue edge includes a vertical distal surface, substantially vertical to the upper and lower surfaces; a flat upper inclined surface extending from the vertical distal surface toward the upper surface; a vertical flange extending downward from the upper surface; a channel disposed substantially between the flat upper inclined surface and the upper surface, the channel comprising a channel bottom and a channel back, the channel back extending from the channel bottom toward the vertical flange;a pinnacle rail connecting the upper flat inclined surface and the channel, wherein the channel bottom extends vertically below the pinnacle rail, and the back of the channel extends laterally farther from the vertical distal surface than the vertical flange; a lower flat inclined surface extending from the vertical distal surface to the lower surface; and a vertical projection extending from the lower flat inclined surface to the lower surface. U.S. Patent No. 6,558,795 for a Strippable Coating System, issued May 6, 2003, to Keith E. Olson et al., provides a radiation-curable coating containing an agent that imparts increased peelability to the cured coating. The agent may be incorporated into the coating or into one or more subsequently applied maintenance layers. The curable coating may be water-based, composed of inorganic particles, and the peelability-improving agents may enhance the adhesion of a radiation-curable maintenance layer to the cured coating. The agent may further comprise a chain-transfer agent that reduces the molecular weight of the cured coating and, in a preferred embodiment, may contain an alcohol, ester, aldehyde, or a mixture thereof. U.S. Patent No. e6,730,388 for Coating Having Macroscopic Texture and Process for Making Same, issued on May 4, 2004, to Richard C. MacQueen et al., provides, in one embodiment, a coated substrate comprising a substrate, a radiation-cured coating, or a thermally cured coating on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture. In another embodiment, the invention provides a pre-cured coating mixture comprising a radiation-curable resin and an initiator, or a thermally curable resin and a thermal initiator, wherein the radiation- or thermally curable resin and the respective initiator form a pre-cured coating mixture capable of forming a macroscopic texture upon application of the mixture to a substrate.In another embodiment, a pre-cured coating mixture is provided comprising a radiation- or thermally curable resin, an initiator, and texture-producing particles having an effective size to provide a macroscopic texture after application of the mixture to a substrate. In another embodiment, the invention provides a coated substrate comprising a substrate and a radiation- or thermally cured coating on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture.In addition, a process is provided for making a coating on a substrate, comprising the steps of distributing a pre-cured coating mixture comprising a radiation-curable resin and an initiator or a thermally curable resin and a thermal initiator onto at least a portion of a substrate to form a pre-cured coating having a macroscopic texture, and radiation-curing or thermally curing, respectively, the pre-cured coating to form a radiation-cured or thermally cured coating having the macroscopic texture. The Chinese publication N.e204920130 for Porcelain Timber Apron Brick, published on December 30, 2015, by Yang P., unveils a porcelain timber apron brick consisting of a ceramic tile layer, a wood panel layer, and a waterproof layer. The wood panel layer and the waterproof layer are fixed to either side of the ceramic tile layer, with the wood panel layer positioned on top of the ceramic tile layer. In Yang's product, the combined thickness of the wood panel layer and the waterproof layer is less than the thickness of the ceramic tile layer. The wood panel layer prevents the surface temperature of the brick from becoming excessively low, improving comfort during use. The waterproof layer effectively prevents water from the floor from penetrating the ceramic tile and wood panel layers, ensuring the tile's waterproof performance.Chinese publication N.s201972361 for Wood and Ceramic Composite Floor Tile, published on September 14, 2011, by Liang Y., discloses a wood and ceramic composite floor tile comprising a core material, a panel, and a backing plate, in which the core material is arranged between the panel and the backing plate. The core material is connected to the panel and the backing plate, respectively, via an adhesive layer, and is one or more ceramic tiles. Frame bars are also provided and arranged around the periphery of the core material. The tile aims to overcome the problems of existing wood and ceramic composite floor tiles, namely that they are easily damaged and have high manufacturing costs.The unveiled tile provides a composite floor tile that is difficult to damage, easy to process, convenient to install and has high «yfrnLn / Lznz / e / YiAi non-deformability characteristics, thus effectively reducing tile costs. U.S. Patent No. 28,166,718 for Horizontally Engineered Hardwood Floor and Method of Installation, issued May 1, 2012, to David C. Liu, provides a flooring panel that includes a decorative top layer supported by a plurality of battens. The plurality of battens is arranged so that some are oriented along the X-axis and others along the Y-axis. The plurality of battens also has features that allow the wood flooring panel to be installed like a tile. Specifically, Liu's patent includes a high-performance engineered wood flooring panel having a length comprising (1) a top wood layer with wood grain aligned along the length of the flooring panel, the top wood layer having a top surface and a bottom surface;(2) a plurality of support strips joined beneath the top layer of wood, a first subset of the plurality of support strips being oriented in a first direction and a second subset of the plurality of support strips being oriented in a second direction, the first subset of the plurality of support strips being physically separated from and not in contact with the second subset of the plurality of support strips, wherein the top layer of wood substantially covers the first and second subsets of support strips;and (3) an adhesive layer placed between the top layer of wood and the plurality of support battens. The adhesive layer covers the underside of the top layer of wood. In addition, a first support batten in the plurality of support battens has a locking flange, and a second support batten in the plurality has a mortise groove, and the locking flange of the first support batten of the high-performance engineered wood floor panel can engage with the mortise groove of the second support batten of the floor panel. International Publication No. 2WO 2005 / 116362 for A Ceramic Wood Laminated Floor, published on December 8, 2005 by Delong Tao, discloses a floor consisting of a base layer made of ceramic tile and a top layer made of wood or bamboo. An adhesive layer is placed between the top layer and the base layer. The underside of the base layer is fitted with an elastic pad. Summary of the invention «yfrnLn / Lznz / e / YiAi This invention provides a method for producing a dust-free and glue-free PVC-based composite flooring material system that has waterproof layers providing different qualities of hardness, wear resistance, soundproofing, and decorative patterns, with layers fused together without glue or adhesives, with a UV-cured top coating, optional interchangeable design printing and texturing, and optionally with an underlayment layer, which can be manufactured in sheet form, essentially continuously, with the ability to quickly and easily change the optional design printing and texture produced, producing a durable and high-performance flooring product. This invention avoids the use of water-permeable compressed cellulosic material such as sawdust filler, which is susceptible to water damage such as swelling and cracking. This invention also avoids the use of glue or adhesive, which is susceptible to premature failure by delamination and increases manufacturing costs and complexity. The flooring material provides a floor covering free of water-based materials such as water-based inks or dyes. The desirable qualities of both compressed powder filler and glue or adhesive are provided in novel ways. Brief description of the drawings Reference will now be made to the drawings, in which similar parts are designated by similar numbers, and in which: Figure 1 is a schematic cross-sectional view of an embodiment of the dust-free and glue-free composite flooring material system of the invention; Figure 2 is an exploded schematic view of an embodiment of the dust-free and glue-free composite flooring material system of the invention; Figure 3 is an exploded schematic view of embodiments of the dust-free and glue-free composite flooring material system of the invention; Figure 4 is a schematic cross-sectional view of another embodiment of the dust-free and glue-free composite flooring material system of the invention, which imitates terrazzo; Figure 5 is a schematic cross-sectional view of another embodiment of the dust-free and glue-free composite flooring material system of the invention, which o;frnLn / Lznz / e / YiAi imitates marble; Figure 6 is a schematic cross-sectional view of an embodiment of the dust-free and glue-free composite flooring material system of the invention, having a unique extruded base layer; Figure 7 is a schematic cross-sectional view of an embodiment of the dust-free and glue-free composite flooring material system of the invention, having a double extruded base layer; and Figure 8 is a flow diagram representation of the production method of the dust-free and glue-free composite flooring material system of the invention. Detailed description of the invention With reference to all figures in general, realizations of the dust-free and glue-free composite flooring system 100 and the production method 200 are illustrated. With reference to Figure 1 and Figure 2, the Dust-Free, Glue-Free Composite Flooring System 100 comprises three waterproof layers 20, 30, and 40 of different materials strongly bonded together without the use of separate glues or adhesives, and an optional underlayment layer 10. The optional underlayment layer 10 can be a natural material such as cork or rubber, or a synthetic material such as open-cell or closed-cell plastic foam. Ethylene vinyl acetate (EVA) is a suitable material. The Dust-Free, Glue-Free Composite Flooring System 100 provides a waterproof coating for any type of optional underlayment layer 10 used, allowing the use of water-sensitive materials for the underlayment. The optional underlayment layer 10 can be omitted, bonded to the finished floor during manufacturing, or made available as a separately packaged item.Depending on the ability of any particular underlayment material to withstand the hot-fusion overlay process disclosed below, the underlayment can be attached to the rest of the dust-free, glue-free 100 composite flooring system earlier or later in the manufacturing process. The dust-free and glue-free composite flooring system 100 provides a 20 waterproof floor base layer, which is formed by melting, extrusion, and molding, forming a combined mixture of PVC resins and other materials according to the method of the dust-free and glue-free composite flooring system «yfrnLn / Lznz / e / YiAi 200 (illustrated in Figure 8 and discussed in more detail below). Optionally, two or more different blends of PVC resins and other fusion-compatible materials can be coextruded in the same mold, producing a fused floor base layer 20 with different sublayers or strata, such as the first base extrusion 21 and the second base extrusion 22 illustrated. The PVC resin blend can be adjusted by using different materials and fillers, or different proportions of materials and fillers, to have different properties when fused and extruded. If a PVC resin blend produces the desired hardness and stability but is deficient in soundproofing or other porosity qualities, then a different PVC resin blend or a different extrusion technique, such as coextrusion, can be applied to provide the otherwise lacking qualities.In a preferred coextruded embodiment, a stiffer, harder layer is formed for strength, and a more elastic layer of dense foam is formed to dampen and absorb sound. The ability to adjust the characteristics of the waterproof soil base layer 20, and therefore the finished floor overall, by adjusting one or more PVC resin blends and one or more extrusion methods eliminates the need for compressed powder, which is vulnerable to moisture and otherwise problematic in some climates and for some applications. For example, forming a controlled amount of a dense foam consistency in the soil base layer 20, either throughout the entire layer or layered within it, depending on the concurrent need for stiffness, can duplicate the desirable qualities of a compressed powder core, but without the disadvantages of powder. In one of the preferred embodiments, the mixture of melt-compatible materials included in a suitable 20 soil base layer is: (a) 50 kg of PVC; (b) 100-175 kg of 800-1000 mesh calcium carbonate (CaCO3); (c) 3.8-5.0 kg of calcium / zinc heat stabilizer; (d) 2.5-5.0 kg of chlorinated polyethylene elastomer; (e) 1.0-4.0 kg of acrylic polymer modifier; (f) 0.4-0.6 kg of internal lubricant; and (g) 0.5-1.5 kg of high melt-point polymer; and, optionally, (h) 0.2-0.3 kg of high-density polyethylene oxide. In preferred embodiments, the PVC mixture comprises, by weight: between 20% and 35% polyvinyl chloride, between 63% and 73% calcium carbonate, between 2% and 2.5% calcium / zinc heat stabilizer, between 1.6% and 2.5% chlorinated polyethylene elastomer, between 0.6% and 1.7% acrylic polymer modifier, between 0.2% and 0.25% internal lubricant, between 0.32% and 0.62% high melting point polymer, and optionally between 0.06% and 1.22%, and optionally between 0.1% and 0.12% high density polyethylene oxide. This mixture is suitable for an individually extruded base layer or for a coextruded layer or multiple coextruded layers. The production method for the dust-free, glue-free, waterproof flooring material system involves mixing the materials for the 20-layer base layer in a suitable large container until thoroughly blended. Then, either in the same large container or a different one, the melting stage involves heating the material mixture while continuing to mix it. A preferred embodiment of the method heats the mixture to 115–130°C while stirring at a high speed approaching, but not exceeding, 1600 RPM. Once melting is complete, the molten PVC material is allowed to cool slightly.PVC material is intended to be reheated during the extrusion process. Therefore, if the batch of molten mix is ​​to be sent immediately to the extruder, the molten mix must be cooled sufficiently to be safely and efficiently transported from the dusty mixing and melting area to the cleaner environment of the extrusion and molding area. This transport or supply can be accomplished using a large pipeline, as is known in the art. Water or another coolant can be circulated in a jacket around the vessel used for melting to draw heat away from the molten PVC mix, taking care not to force excessively rapid cooling, which could impair the plastic properties of the soil base layer. The mixing, melting, and cooling stages are, by nature, batch processes. However, through careful adjustment and control of the processes, or by establishing more than one production line and staggering their operation, an essentially continuous supply of molten PVC material can be produced and supplied to downstream operations. The molten PVC mixture is conveyed to a screw extruder for extrusion into an extrusion die at elevated temperature and pressure. A preferred embodiment is extruded using an 80 mm diameter screw at a speed not exceeding 40 RPM, an extrusion pressure of 20–35 MPa, and a temperature of 160–186 °C. More than one mixture can be co-extruded into the same extrusion die to form different layers, as previously disclosed. This extrusion and mold-forming process produces a sheet of the soil base layer 20. The sheet can be very long or essentially continuous.If the mixing-melting-cooling-supplying stages of the process are properly coordinated to provide a continuous supply of molten PVC material to the screw extruder, then the extruder can supply an essentially continuous sheet of the base layer of soil 20 for the hot-melt overlay of an essentially continuous sheet of the front layer of soil 30. The flooring face layer 30 comprises a decorative face layer 31 fused to a wear face layer 32. The decorative face layer 31 can be formed from a decorative PVC film and is typically opaque and a color that serves as a base or background color for any decorative pattern 33 intended to be applied, such as wood, stone, or tile imitations, or other decorative patterns. The wear face layer 32 can be formed from a wear-resistant, high-molecular-weight PVC polymer film, typically clear or mostly transparent, so that the decorative face layer 31 is visible. In most embodiments of the dust-free, glue-free composite flooring system 100, a decorative pattern 33 is applied to the decorative face layer 31 before it is fused to the wear face layer 32.The decorative pattern 33 is likely an imitation of traditional flooring materials such as wood, stone, or tile. With brief reference to Figure 3, which schematically illustrates that the surface layer of flooring 30 could have a decorative pattern imitating marble, terrazzo, or wood, different decorative patterns 33 can be used with the dust-free, glue-free composite flooring system 100. The patterns can be applied using a printing roller or a digital image printing device. One advantage of digital printing is that it can produce an image with no exact repeat or with a very long repeat interval, in contrast to the inherent repeatability of roller printing.Another advantage of digital printing is that several different colors, shades, or tones can be applied or even mixed in place, which is very cumbersome or not possible with roller printing in a floor-based manufacturing environment. The decorative PVC film that forms the decorative front underlay 31 can be supplied in large rolls. The strength and wear characteristics of this decorative PVC film do not significantly influence the strength and wear characteristics of the finished flooring, as other elements provide these characteristics. In practice, the decorative PVC film must be strong enough to prevent tearing during the flooring manufacturing process. The use of a wear-resistant, high-molecular-weight PVC polymer film for the front wear sublayer 32 provides a significant portion of the desired wear resistance of the finished floor, with the floor coating layer 40 providing the remainder. This film can also be supplied in large rolls. An essentially continuous sheet of the 30-grade floor front layer can be produced using large rolls of PVC film, or by having an efficient reloading method. Although the wear-resistant front underlay 32 can be fused to the decorative front underlay 31 as a separate stage in the manufacturing process, before being subsequently fused to the floor base layer 20, a preferred embodiment of the dust-free, glue-free composite flooring system method 200 provides simultaneous fusion of the wear-resistant front underlay 32, the decorative front underlay 31, and the floor base layer 20 in one pass. This fusion is achieved by hot-fusion layering, bringing the underlays and layers into contact with each other in the correct order, and simultaneously heating and applying compression to the stack to fuse the layers together without the use of glue or adhesive, thereby essentially eliminating potential problems of delamination or other finished floor defects.Hot melt lay-up can be carried out by supplying the wear front sub-layer 32, the decorative front sub-layer 31, and the floor base layer 20 on a set of heated rollers. When the wear front sub-layer 32 and the decorative front sub-layer 31 are supplied as large rolls of PVC polymer films of essentially equal width, and the floor base layer 20 is formed into sheets of essentially the same width as the film rolls, or into divisions of that width that allow simultaneous side-by-side processing of multiple sheets, hot melt lay-up can be carried out in a continuous or near-continuous series. Optionally, a textured, embossed, synchronized embossed, embossed, or synchronized embossed surface pattern may be applied to the face layer of the fused base and face layers. Such a texture may be an imitation decorative texture that complements or is synchronized with a printed decorative pattern, or it may be a texture intended to enhance traction, light reflection, or other qualities of the finished floor. The textured, embossed, synchronized embossed, embossed, or synchronized embossed surface pattern may be applied to the face layer of the fused base and face layers either simultaneously with the hot-fusion overlap compression stage or immediately thereafter, while the face layer is still partially fused and flexible.The hot-melt roller(s) that make contact with the front layer of soil 30 can be configured to emboss the texture, although this arrangement would require a short period of texturing repetition or a large roller. Embossing can be performed using one or more rollers, plates, or other devices, such as rakes, that press the front layer of soil 30 from the now-fused base and front layers immediately after the hot-melt overlap compression, while the partial assembly is still flexible. Depending on the amount and nature of the texturing, rigid wire cylinders could be used as embossing rollers, perforated cylinders could be used, or a rake arrangement could be used, possibly allowing movement of the tines to create variation. Hot-fusion overlay fuses the 30-grade floor face layer and the 20-grade floor base layer together without the use of glue or adhesive. The face and base subassembly emerges from the hot-fusion overlay and optional texturing at a very high temperature. The face and base subassembly is then conditioned. This conditioning stage allows the face and base subassembly to cool to ambient temperature slowly and evenly, without quenching or other sudden cooling, in order to prevent stress development in the sheet. Because the face and base subassembly is a thin sheet that almost completely covers the surface area, cooling does not require an excessive amount of time, and the conditioning process can be carried out continuously by providing sufficient additional conveyor belt length to allow for cooling.Optionally, additional conditioning procedures such as corona discharge or flame treatment can be performed to prepare the PVC surface for application of the 40 floor covering layer. The optional 10 underlayment layer can be added to the subassembly at this point or later points after the hot-fusion overlay and optional texturing have been performed. An essentially continuous sheet of the front and base subassembly can be produced by the hot melt overlap stage if there is a continuous supply of base layer and front layer sheet. After the facing and base subassembly has cooled in the conditioning stage, the subassembly is then coated with a plastic resin that can be cured under ultraviolet (UV) light, forming a flooring coating layer. UV-cured primers and topcoats suitable for application over PVC are known in the art. Generally, the UV-cured primer and topcoat will be clear, colorless, and transparent, allowing the decorative pattern to show through. Generally, colorless coatings can be cured more quickly and with less exposure than colored coatings. UV-cured topcoats are available that provide a glossy or matte finish and have desirable properties such as scratch resistance.Optionally, a sandy particulate material such as aluminum oxide or ceramic powder, or another anti-abrasive material, can be added to the UV-cured plastic resin and incorporated into the 40 floor coating layer to provide additional traction and wear resistance. In a preferred embodiment, the UV primer and UV topcoats are applied using a series of rollers in long runs or a continuous run. There must be an application of UV-cured primer and at least one application of UV-cured topcoat, although more than one UV-cured topcoat will likely improve the appearance and durability of the finished floor. Curing is effected by exposure to UV light from, for example, mercury (Hg) or gallium (Ga) lamps. UV curing occurs very rapidly, in just a few seconds, and can be achieved in the time it takes for a workpiece to move on a conveyor belt past a bank of UV lights. In contrast, oxidative curing of polyurethane is likely to take eight to ten hours, and curing of a two-component epoxy will likely take at least thirty minutes or more. The use of UV-cured plastic resins in the 40-layer floor covering of the 200 dust-free, glue-free composite flooring system method eliminates a potential bottleneck in the manufacturing process, enabling the production of an essentially continuous sheet of fully assembled, fused, decorated, coated, and cured flooring material. Coating and UV curing of the fused base and face subassembly produce a finished large sheet assembly of composite flooring material incorporating the 20-layer floor covering, 30-layer floor facing, and 40-layer floor covering, with an optional 10-layer underlayment. This finished large sheet assembly is intended to be split into segments of the desired size and configuration, such as a tile or plank, which can be easily handled during installation, or into a large rolled sheet. The final stages in the Dust-Free, Glue-Free Composite Flooring System 200 method involve profile processing, where the large sheet of finished flooring material is cut to the desired size and the appropriate notches, grooves, tabs, or other installation-related features are formed. Optionally, bevels can be processed on two or four sides of the profiled flooring material, painted in various colors, sometimes to mimic designs found in wood, tile, fabric, or marble, such as gray bevels to simulate grout lines between tiles and black or dark colors to simulate French bleed on wood. From a profile view, the bevels can have different shapes, such as straight lines forming angles, or square or rounded arcs. The finished flooring material is then inspected and packaged for shipping and sale. With reference to Figure 8, a flow diagram representation of the production method for the dust-free and glue-free composite flooring system 200, the base layer of flooring 20 is formed from PVC and other raw materials by mixing, melting, cooling, supplying, extrusion, mold forming, and conditioning-cooling, producing a sheet-like supply of the base layer of flooring 20 that can be essentially continuous. The "yfrnLn / Lznz / e / YiAi" face layer of flooring 30 is formed separately, and potentially simultaneously, by providing a decorative PVC film, optionally printing a decorative pattern 33 on it, and then adding a wear-resistant PVC film, producing a sheet-like supply of the face layer of flooring 30 that can also be essentially continuous.Next, the sheets of the 20-layer flooring base and 30-layer flooring face layer are brought together in the appropriate orientation and fused together, without glue or adhesives, by hot-melt overlapping, optionally followed by texturing. This produces a sheet-like supply of a base and face subassembly that can also be essentially continuous. A conditioning stage then allows the hot-melt base and face subassembly to cool and, optionally, provides further conditioning procedures. A layer of UV-cured plastic resin is then applied as a primer coat, followed by at least one topcoat. After each application of UV-cured plastic resin, the coated flooring sheet undergoes UV curing by exposure to UV light, resulting in very rapid curing.The conditioning, coating, and UV curing processes can be performed on an essentially continuous sheet supply of a base and facing subassembly, producing a sheet supply of finished, cast, coated, and cured flooring material that can also be essentially continuous. The finished flooring sheet is then cut to size and has notches, grooves, or tabs formed for installation purposes during the profile processing stage. Inspection and packaging of the profiled flooring material pieces are the final stages. The Dust-Free, Glue-Free Composite Flooring System 200 method provides the ability to manufacture flooring on a continuous assembly line conveyor belt. It also allows for efficient production changeovers from one color or design pattern to another. This method produces a flooring material product that is dust-free and glue-free, yet possesses the desirable qualities associated with powder and glue, achieved through innovative means. It is anticipated that digital printing can be applied to the base layer of flooring 20. In such cases, a hydro-UV primer is applied beforehand to ensure good adhesion properties, followed by UV putty "yfrnLn / Lznz / e / YiAi" to create a smooth base. Next, a UV sealer is applied to create a standard white base for priming over PVC. Especially with digital printing, the design options are virtually limitless. Before printing, the desired texture can be achieved using various rollers to create the desired texture, such as smooth, hand-scraped, embossed, line-marked, saw-marked, BP, and wood grain. After printing, an anti-abrasive sealer, sanding sealer, structural coating, and anti-scratch topcoat are applied, providing a scratch-resistant and anti-abrasive wear layer.In this case, the front layer 10 of floor 30, which has a decorative PVC film and a wear-resistant high molecular weight polymeric PVC film, may not be necessary. Many other changes and modifications can be made to the present invention without departing from its spirit. Therefore, we request that our rights in the present invention be limited only to the scope of the 15 appended claims. o;frnLn / Lznz / e / YiAi

Claims

1. A method for producing a dust-free and glue-free composite flooring material, comprising the steps of: (i) forming a waterproof base layer of flooring by: (a) providing a first mixture of PVC resin free from compressed cellulosic material and adhesive and having fusion-compatible materials, providing a second mixture of PVC resin free from compressed cellulosic material and adhesive and having fusion-compatible materials, separately mixing the first and second mixtures of PVC resin and fusion-compatible materials,producing two PVC resin blends having different physical characteristics; (b) separately fusing the first and second PVC resin blends by applying heat and continuous mixing; (c) cooling the molten PVC resin blends; (d) supplying the cooled molten PVC resin blends to another area for further processing; (e) co-extruding the supplied cooled molten PVC resin blends in the same mold at elevated temperature and pressure and producing a molten extrudate with a first base extrusion sub-layer and a second base extrusion sub-layer; (f) molding the extruded molten PVC resin blend into a sheet of said base floor layer; and (g) cooling the sheet of said base floor layer; (ii) forming a waterproof front floor layer,by: (a) providing a decorative PVC polymer film and a wear-resistant PVC polymer film; and (b) adding the wear-resistant PVC polymer film to the top surface of said decorative PVC polymer film; (iii) hot-fusing said flooring face layer and said flooring base layer, producing a sheet-shaped base and face subassembly; (iv) conditioning said sheet-shaped base and face subassembly; or (v) coating said sheet-shaped base and face subassembly with a UV-cured plastic resin, thereby forming a waterproof flooring coating layer; (vi) UV-curing said UV-cured plastic resin coating by exposure to UV light, producing a finished large sheet assembly; (vii) profile-processing said finished large sheet assembly, producing multiple composite flooring material segments of the desired size and shape,thus producing a water-based, impermeable floor covering; (viii) inspecting said segments of composite flooring material; and (ix) packaging said segments of composite flooring material; wherein the formation of said front flooring layer and the formation of said base flooring layer can be carried out simultaneously, providing a supply of both for the hot-melt overlay stage of said front flooring layer and said base flooring layer; wherein said hot-melt overlay stage of said front flooring layer and said base flooring layer accommodates an essentially continuous supply of said front flooring layer and said base flooring layer,and produces an essentially continuous supply of said sheet-formed base and face subassembly; wherein said conditioning step of said sheet-formed base and face subassembly can be carried out without slowing down or stopping the rate of the essentially continuous supply of said sheet-formed base and face subassembly; wherein said coating step of said sheet-formed base and face subassembly can be carried out at the rate of the essentially continuous supply of said sheet-formed base and face subassembly; and wherein said UV curing step of said coating can be carried out at the rate of the essentially continuous supply of said sheet-formed base and face subassembly.

2. The method for producing the dust-free and glue-free composite flooring material of claim 1,wherein said step of forming the base floor layer further comprises the steps of forming a first extruded base sub-layer and a second co-extruded base sub-layer fused on top of the first base sub-layer, each sub-layer being formed by mixing, melting, cooling, supplying, and co-extrusion, followed by forming in a common mold, the second co-extruded sub-layer having a mixture comprising PVC resin and fusion-compatible materials adapted to provide additional desired qualities in said base floor layer in use.

3. The method for producing the dust-free and glue-free composite flooring material of claim 1, further comprising fixing a subfloor layer.

4. The method for producing the dust-free and glue-free composite flooring material of claim 1,wherein said decorative PVC polymer film further comprises a colored film.

5. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said formation of a decorative flooring layer further comprises printing a design onto said decorative PVC polymer film before the addition of said wear-resistant PVC polymer film.

6. The method for producing the dust-free and glue-free composite flooring material of claim 1, further comprising a step of texturizing the front surface of said sheet-shaped base and face subassembly after said hot-melt overlay step and before completing said conditioning.

7. The method for producing the dust-free and glue-free composite flooring material of claim 1,wherein said wear-resistant PVC polymer film is transparent.

8. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said flooring coating layer is transparent.

9. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said flooring coating layer further comprises a sandy particulate material.

10. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said flooring coating layer further comprises aluminum oxide.

11. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said PVC resin mixture comprises: (1) 50 kg of polyvinyl chloride (PVC); (2) 100-175 kg of 800-1000 mesh calcium carbonate; (3) 3.8-5.0 kg of calcium / zinc thermal stabilizer; (4) 2.5-5.0 kg of chlorinated polyethylene elastomer; (5) 1.0-4.0 kg of acrylic polymer modifier; (6) 0.4-0.6 kg of internal lubricant; and (7) 0.5-1.5 kg of high melting point polymer. «yfrnLn / Lznz / e / YiAi 12. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said PVC resin mixture comprises: (1) 50 kg of polyvinyl chloride (PVC); (2) 100-175 kg of 800-1000 mesh calcium carbonate; (3) 3.8-5.0 kg of calcium / zinc heat stabilizer; (4) 2.5-5.0 kg of chlorinated polyethylene elastomer; (5) 1.0-4.0 kg of acrylic polymer modifier; (6) 0.4-0.6 kg of internal lubricant; (7) 0.5-1.5 kg of high-melting-point polymer; and (8) 0.2-0.3 kg of high-density polyethylene oxide.

13. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said flooring coating layer further comprises an application of UV-curing primer and at least one application of UV-curing topcoat.

14. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said UV curing further comprises exposure to mercury (Hg) lamps.

15. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein said UV curing further comprises exposure to gallium (Ga) lamps.

16. The method for producing the dust-free and glue-free composite flooring material of claim 1,wherein the formation of said base flooring layer further comprises a step of heating the mixture to 115-130°C while stirring at a high speed approaching but not exceeding 1600 RPM.

17. The method for producing the dust-free and glue-free composite flooring material of claim 1, wherein the hot-fusion layering of said surface flooring layer and said base flooring layer further comprises a step of passing the assembled surface flooring layer and surface flooring layer through at least one set of heated rollers.

18. A method for producing a dust-free and glue-free composite flooring material, comprising the steps of: (i) forming a waterproof base flooring layer by: (a) providing a first mixture of PVC resin free from compressed cellulosic material and adhesive and having fusion-compatible materials,(a) providing a second PVC resin blend free of compressed cellulosic material and adhesive and containing melt-compatible materials, separately blending the first and second PVC resin blends and compatible materials, producing two PVC resin blends with different physical characteristics; (b) separately fusing the first and second PVC resin blends by applying heat and continuous mixing; (c) cooling the molten PVC resin blends; (d) supplying the cooled molten PVC resin blends to another area for further processing; (e) co-extruding the supplied cooled molten PVC resin blends in the same mold at elevated temperature and pressure and producing a molten extrudate with a first base extrusion sublayer and a second base extrusion sublayer.wherein the extrusion of said base layer further comprises extrusion using an 80 mm diameter screw at a speed not exceeding 40 RPM, an extrusion pressure of 20-35 MPa and a temperature of 160-186 °C; (f) molding the extrudate of the extruded molten PVC resin mixture into a sheet of said base layer; and (g) cooling the sheet of said base layer; (ii) forming a waterproof surface layer by: (a) providing a decorative PVC polymer film and a wear-resistant PVC polymer film; and (b) adding the wear-resistant PVC polymer film to the upper surface of said decorative PVC polymer film; (iii) hot-fusion-bonding said surface layer and said base layer,producing a sheet-shaped base and face subassembly; (iv) conditioning said sheet-shaped base and face subassembly; (v) coating said sheet-shaped base and face subassembly with a UV-curing plastic resin, thereby forming a waterproof floor coating layer; (vi) UV-curing said UV-curing plastic resin coating by exposure to UV light, producing a finished large sheet assembly; (vii) profile processing said finished large sheet assembly, producing multiple segments of composite flooring material of the desired size and shape,thus producing a water-based, impermeable floor covering; (viii) inspecting said segments of composite flooring material; and (ix) packaging said segments of composite flooring material; wherein the stage of forming said front flooring layer and the stage of forming said base flooring layer can be carried out simultaneously, producing a supply of both to said hot-fusion overlay process; wherein said hot-fusion overlay stage of said front flooring layer and said base flooring layer accommodates an essentially continuous supply of said front flooring layer and said base flooring layer,and produces an essentially continuous supply of said sheet-formed base and face subassembly; wherein said conditioning step of said sheet-formed base and face subassembly can be carried out without slowing down or stopping the rate of the essentially continuous supply of said sheet-formed base and face subassembly; wherein the coating step of said sheet-formed base and face subassembly can be carried out at the rate of the essentially continuous supply of said sheet-formed base and face subassembly; and wherein the UV curing step of said coating can be carried out at the rate of the essentially continuous supply of said sheet-formed base and face subassembly.

19. The method for producing the dust-free and glue-free composite flooring material of claim 1,wherein said wear-resistant PVC polymer film and said decorative PVC polymer film are supplied in large rolls.

20. A method for producing a dust-free and glue-free composite flooring material, comprising the steps of: (i) forming a waterproof floor base layer by: (a) providing a first PVC resin mixture free from compressed cellulosic material and adhesive and having fusion-compatible materials, providing a second PVC resin mixture free from compressed cellulosic material and adhesive and having fusion-compatible materials, separately mixing the first and second mixtures of PVC resin and fusion-compatible materials, producing two PVC resin mixtures having different physical characteristics, each PVC resin mixture comprising, by weight, at least the following ingredients: between 20% and 35% polyvinyl chloride,between 63% and 73% calcium carbonate, between 2% and 2.5% calcium / zinc heat stabilizer, between 1.6% and 2.5% chlorinated polyethylene elastomer, between 0.6% and 1.7% acrylic polymer modifier, between 0.2% and 0.25% internal lubricant, and between 0.32% and 0.62% high melting point polymer; (b) separately fusing the first and second PVC resin blends by applying heat and continuous mixing; (c) cooling the molten PVC resin blends; (d) supplying the cooled molten PVC resin blends to another area for further processing; (e) co-extruding the supplied cooled molten PVC resin blends in the same mold at elevated temperature and pressure and producing a molten extrudate with a first base extrusion sub-layer and a second base extrusion sub-layer; (f) molding the extruded molten PVC resin blend into a sheet of said base floor layer; and (g) cooling the sheet of said base floor layer; and (ii) forming a waterproof front floor layer,by: (a) providing a decorative PVC polymer film and a wear-resistant PVC polymer film; and (b) adding the wear-resistant PVC polymer film to the top surface of said decorative PVC polymer film; (iii) hot-fusing said flooring face layer and said flooring base layer, producing a sheet-shaped base and face subassembly; (iv) conditioning said sheet-shaped base and face subassembly; (v) coating said sheet-shaped base and face subassembly with a UV-cured plastic resin, thereby forming a waterproof flooring coating layer; (vi) UV-curing said UV-cured plastic resin coating by exposure to UV light, producing a finished large sheet assembly; (vii) profile-processing said finished large sheet assembly, producing multiple composite flooring material segments of the desired size and shape,thus producing a water-based, impermeable floor covering; (viii) inspecting said composite flooring material segments; and (ix) packaging said composite flooring material segments; wherein the stage of forming an impermeable soil base layer and the stage of forming said soil base layer can be performed simultaneously, producing a supply of both to said hot-fusion overlay process; wherein said hot-fusion overlay stage of the soil front layer and the soil base layer accommodates an essentially continuous supply of said soil front layer and said soil base layer,and produces an essentially continuous supply of said base and faceplate subassembly in sheet form; wherein said conditioning process can be carried out without slowing down or stopping the rate of the essentially continuous supply of said base and faceplate subassembly in sheet form; wherein said coating process can be carried out at the rate of the essentially continuous supply of said base and faceplate subassembly in sheet form; and wherein the UV curing stage can be carried out at the rate of the essentially continuous supply of said base and faceplate subassembly in sheet form. «yfrnLn / Lznz / e / YiAi,