Dimensionally stable floor panels

Abstract

Floor panels are provided. A composition of a floor panel includes a wear resistant layer and a base layer. The base layer includes a first base section having a first composition of polyvinyl chloride, a filler, and a plasticizer, a second base section having a second composition of polyethylene and a plasticizer in a higher content than the first composition, and a glass fiber section having a lower content than the second composition. The glass fiber section is located between the first base section and the second base section.

Description

[0001] This application is a divisional application of the patent application with application number 201780064192.4 and invention name “Dimensionally Stable Floor Inlay”, whose applicant is “Novalis Co., Ltd.” and whose entry date into the Chinese national phase is April 17, 2019 (international application date is October 17, 2017, and international application number is PCT / IB2017 / 001413).

[0002] CROSS REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 62 / 408,998, filed on October 17, 2016, under 35 U.S.C. §119(a)-(d). Technical Field

[0004] The present invention generally relates to floor panels and, more particularly, to a dimensionally stable floor panel composition having a reinforcement layer with a leading edge. Background Art

[0005] Luxury vinyl tile ("LVT") is generally well known and is a fairly popular flooring choice. LVT can be manufactured to have the natural look of wood, stone, slate, brick, ceramic, or many other designs, as long as the natural look can be printed on the film through rotogravure printing, digital printing, and many other ways. The flooring is designed to have the resilience and durability of hard-wearing vinyl flooring. Although adhesives and locking systems are generally used during the installation of LVT, loose floating installation has become more popular considering the simplicity and efficiency during installation.

[0006] Loose-lay tile ("LLT") products are simply laid on a floor or subfloor and snugly mounted on a wall. LLT requires several key features in terms of characteristics: (1) a low coefficient of expansion and contraction, (2) a heavy fiberglass face veil that provides optimal dimensional stability and fixed placement, (3) flatness that creates the illusion of a large installed floor like a monolithic floor sheet, and (4) a non-slip backing that further improves its fixed placement. However, even with excellent flatness characteristics, deformation is often caused by unintentional errors during packaging and storage. Edge lifting and curling problems often occur and are more prominent during shipping, especially in cold climate conditions. Not only are these problems visually unpleasant and annoying, they also affect installation. Because the solution is time-consuming and costly, there is no other benefit other than maintaining curling. Summary of the invention

[0007] Therefore, the present invention has been devised in view of the above problems, to provide a dimensionally stable floor panel composition having a reinforcing layer with a leading edge.

[0008] Therefore, it is necessary to form a method to overcome edge erection or curling, which is not caused by the product itself but by the complex environment of packaging and transportation. A floor panel is provided. The composition of the floor panel includes a wear layer and a base layer. The base layer includes a first base section, a second base section, and a glass fiber section, the first base section has a first composition of polyvinyl chloride, filler and plasticizer, the second base section has a second composition of polyethylene and plasticizer with a higher content than the first composition, and the glass fiber section is located between the first base section and the second base section. In addition, a protrusion is arranged on one side of the base layer and extends outwardly beyond the top layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will be explained in more detail with reference to embodiments with reference to the accompanying drawings, in which:

[0010] Figure 1 is a top perspective view of a dimensionally stable floor panel according to the present invention;

[0011] Figure 2 yes Figure 1 A bottom perspective view of a dimensionally stable floor panel;

[0012] Figure 3 yes Figure 1 A schematic diagram of a floor panel showing multiple layers of the floor panel;

[0013] Figure 4 yes Figure 1 A cross-sectional view of the floor panel taken along line 4-4;

[0014] Figure 5 yes Figure 1 A close-up view of a portion 5 of a floor panel;

[0015] Figure 6 is a schematic diagram of adjacent floor panels according to the present invention; and

[0016] Figure 7 is a schematic diagram of connecting adjacent floor panels according to the present invention. DETAILED DESCRIPTION

[0017] Surface coverings related to floor coverings, wallpapers, or other surface coverings having a uniform single layer or heterogeneous multi-layer structure will now be discussed. Exemplary embodiments of floor coverings include loose laid luxury vinyl tiles and planks ("LLT") and sheet flooring. However, one of ordinary skill in the art will appreciate that surface coverings may also include other types of coverings, such as carpet backings, wall coverings, semi-rigid extruded sheets, vinyl underlays, and resilient hard surface flooring, such as vinyl composition tiles, inlay products, and cushion flooring.

[0018] Referring now to the drawings, wherein like reference numerals refer to like parts throughout the several views and embodiments.

[0019] In the embodiment shown in the figure, a single floor panel 1 is made of a laminated polymer component. Each floor panel 1 is made of a laminated polymer component, which includes a vinyl formed into several layers. In the embodiment shown, the total thickness of each floor panel is about 3.00-5.00 mm. However, it is also possible to prepare a floor panel 1 with one or more layers, each layer having a different thickness. The composition of the floor panel 1 can also vary, and the floor panel 1 is made of various materials, including but not limited to polymers, ceramics, metals, organic materials, etc.

[0020] However, if Figure 1-4 As shown, the floor panel 1 is prepared with a top layer 10 of a flexible polymer sheet material, a base layer 20 of a stable polymer material, and a backing layer 30 made of a non-slip polymer material. As shown, each of the layers 10, 20 and 30 has a different thickness. However, the layers can have the same thickness. The thickness, layering and preparation of the entire floor panel 1 will meet the parameters of the finished product, including the size. The manufacturing is not for one specific design, but includes the novel design features described in the following paragraphs.

[0021] Additionally, certain embodiments may include copolymers, lubricants, fillers, pigments, or combinations thereof.Amounts of composition ingredients are expressed as parts per hundred by weight of polymer ("phr").

[0022] According to the present invention, the floor panel 1 can be shaped as a square or rectangle with four sides a, b, c, d, each of which is connected by an inner angle (right angle) of 90°. In addition, the floor panel 1 includes a top side 2 and a bottom side 4. In the embodiment shown, the top side 2 is prepared by a top layer 10, and the bottom side 4 is prepared using a backing layer 30.

[0023] like Figure 1-4As shown, the floor panel is made of multiple laminate components. In the embodiment shown, the top layer 10 is prepared to have three components: a thin coating layer 12, a durable wear layer 14, and a printed layer 16, the printed layer 16 having printed features. Any component, such as the thin coating layer 12, the durable wear layer 14, or the printed layer 16, can have a texture to enhance the characteristics of the floor panel 1 structure.

[0024] A thin coating layer 12 and a durable wear layer 14 are disposed on top of the printed layer 16 and, in the illustrated embodiment, are transparent and made of a plastic material having a relatively high durability.

[0025] In the illustrated embodiment, the print layer 16 is provided with a printed pattern, with the underside of the print layer 16 bonded to the base layer 20, with the printed pattern facing away from the backing layer 30. The top layer 10 provides graphic and texture relief, and can be prepared to match any printed or even simulated real metamorphic rock features.

[0026] Although not required, the thin coating 12 may be a polyurethane coating having a thickness of about 0.03 mm. However, the application, composition and thickness of the thin coating 12 may vary with respect to the overall floor panel 1 structure.

[0027] In the illustrated embodiment, the top layer 10 also includes a transparent wear layer 14. The wear layer 14 can be made of polyvinyl chloride or other polymer materials, such as polypropylene. The wear layer 14 is used to protect the printed layer 16. And because the wear layer 14 is transparent or clear, any aesthetic imprint on the printed layer 16 can be seen through the wear layer 14. Although the thickness can vary, the thickness of the wear layer 14 ranges from 0.1-1.5 mm. In the illustrated embodiment, the wear layer 14 has a thickness of about 0.50 mm. However, much like the coating 12, the application, composition and thickness of the wear layer 14 can be prepared according to the overall floor panel 1 structure.

[0028] In one embodiment of the present invention, the composition of the wear layer 14 includes polyvinyl chloride and a plasticizer. The K value of polyvinyl chloride is preferably in the range of 60-70. The plasticizer is preferably a non-phthalate plasticizer, such as DOTP, DINCH and a bio-based plasticizer (i.e., octadecanoic acid, 10-chloro-9-methoxy-methyl ester, etc.). The wear layer 14 may also include a stabilizer, and the stabilizer is preferably a non-heavy metal content stabilizer. For example, calcium / stearate and / or zinc stearate or calcium / zinc combined complex soap systems can be used. In addition, the wear layer 14 may also include a co-stabilizer. For example, epoxidized soybean oil can be used. Lubricants may also be added to the wear layer, such as paraffin. Optionally, a UV stabilizer may also be added to the wear layer 14, which includes a UV absorber and hinders amines to maximize the efficiency of UV stability.

[0029] Table 1 shows exemplary compositions of the wear resistant layer 14 according to the present invention.

[0030] Table 1:

[0031] Element Recipe (phr) PVC 100 Plasticizers 18-32 Heat Stabilizer 1.0-5.0 Co-stabilizer 0.5-3.0 lubricating oil 0.1-1.5 UV Stabilizers 0.1-1.5

[0032] The printed layer 16 may be used to provide the floor panel 1 with a printed graphic that will serve to enhance the aesthetics of the floor panel 1. In this embodiment, the printed layer 16 will be a decorative layer having a printed design on the top surface of the printed layer 16. The thickness of the printed layer 16 may be in the range of 0.07-0.1 mm. However, in an exemplary embodiment, the printed layer 16 has a preferred thickness of about 0.07 mm. Although the top layer 10 is located on top of the base layer 20, the top layer 10 is transparent, allowing any printed pattern on the top surface of the base layer 20 to be easily seen.

[0033] The print layer 16 may be printed by rotogravure printing, flexographic printing, digital printing, or transfer printing.

[0034] In one embodiment of the present invention, the composition of the print layer 16 includes polyvinyl chloride and a plasticizer. In one embodiment of the present invention, the K value of the polyvinyl chloride is in the range of 60-70. The plasticizer is preferably a non-phthalate plasticizer, such as DOTP, DINCH, and a bio-based plasticizer (i.e., octadecanoic acid, 10-chloro-9-methoxy-methyl ester, etc.). A stabilizer may be added to the composition of the print layer 16. It is preferred to use a non-heavy metal content stabilizer, such as a calcium / stearate and / or zinc stearate or calcium / zinc combination complex soap system. The print layer 16 may also include a co-stabilizer. For example, epoxidized soybean oil may be used. Titanium dioxide may also be added to the print layer 16 to increase opacity.

[0035] Table 2 shows exemplary compositions of the print layer 16 according to the present invention.

[0036] Table 2:

[0037] Element Recipe (phr) PVC 100 Plasticizers 0-15 Heat Stabilizer 1.0-5.0 Co-stabilizer 0.5-3.0 Titanium Dioxide 0.1-2.0

[0038] During manufacturing, the top layer 10 (either the print layer 16 alone or a combination of the thin coating 12, the durable wear layer 14, and the print layer 16) can be prepared with texture features to enhance the feel of the floor panel 1. Thus, if the top layer 10 is prepared with a print pattern and a textured surface, the floor panel 1 will have the look and feel of a real wood, ceramic, or metamorphic rock floor. If the print layer 16 is the topmost layer of the floor panel, the print layer 16 should be prepared from a material that has a higher resistance and elasticity than if the print layer 16 is prepared with the top wear layer 10.

[0039] According to the present invention, the base layer 20 is made of multiple polyvinyl chloride layers. In the illustrated embodiment, the base layer 20 includes an upper base segment 22, an intermediate base segment 24, a lower base segment 26, and a fiberglass segment 28. In an exemplary embodiment, the upper base segment 22, the intermediate base segment 24, and the lower base segment 26 have different compositions of polyvinyl chloride and filler.

[0040] In the embodiment shown, the base layer 20 is located between the top layer 10 and the backing layer 30. The base layer 20 is the backbone of the structure because it mainly affects the mechanical properties, such as tear, gouge, indentation resistance, stiffness, flexibility, etc. of the product, as well as cost, weight, dimensional stability, flatness and many other properties. The number of layers in the base layer 20 structure depends on the total thickness of the floor panel 1 (including the thickness of the wear layer 14), the balance of the structure, the formulation of each layer, and the cost of the product.

[0041] The upper base section 22 is the layer directly below the printed layer 16, and includes a composition of polyvinyl chloride and fillers. Other composition elements may be provided, including plasticizers, stabilizers, pigments, and flame retardants.

[0042] The upper base section 22 has a higher filler content per 100 parts of polyvinyl chloride than the middle base section 24 and the lower base section 26. As a result, the upper base section 22 will have less polyvinyl chloride and plasticizer content than the middle base section 24 and the lower base section 26. In the illustrated embodiment, the upper base section 22 provides rigidity and hardness to the floor. Due to the high filler content and the low content of PVC and plasticizer, the thickness of this layer has a great impact on the cost of the overall product.

[0043] In the illustrated embodiment, the upper base section 22 includes polyvinyl chloride, a primary plasticizer, a thermal stabilizer, a co-thermal stabilizer, a filler, a flame retardant, and a pigment. The plasticizer is preferably a non-phthalate plasticizer, such as DOTP, DINCH, and a bio-based plasticizer (i.e., octadecanoic acid, 10-chloro-9-methoxy-methyl ester, etc.). The upper base section 22 may also include a stabilizer, such as a non-heavy metal content stabilizer. For example, the non-heavy metal content stabilizer may be a calcium / stearate and / or zinc stearate or a calcium / zinc combination complex soap system. The upper base section 22 may also include a co-thermal stabilizer, such as epoxidized soybean oil. Fillers may also be added to the upper base section 22. For example, limestone may be used as a filler. Flame retardants such as magnesium hydroxide may be used. Pigments such as carbon black or titanium dioxide may also be added.

[0044] Table 3 shows exemplary compositions of upper base segments 22 according to the present invention.

[0045] Table 3:

[0046] Element Recipe (phr) PVC 100 Plasticizers 25-35 Heat Stabilizer 2.0-5.0 Co-stabilizer 4.0-6.0 filler 300-400 Flame retardants 10-20 pigment 0.3-1.0

[0047] In the illustrated embodiment, the upper base section 26 comprises two layers of material which are then combined with the intermediate base section 24 and the lower base section 26 during manufacture. However, those skilled in the art will appreciate that other designs are possible, including the number of individual layers that make up the upper base section 22.

[0048] As shown, the intermediate base section 24 is located below the upper base section 22. According to the present invention, the intermediate base section 24 has a similar composition to the upper base section 22. However, the composition is changed from a high filler content to a low filler content, and then to a higher polyvinyl chloride content and plasticizer content. As a result, the intermediate base section 24 according to the present invention is well balanced in terms of rigidity, flexibility, elasticity and many other mechanical properties.

[0049] In the illustrated embodiment, the intermediate base section 24 includes polyvinyl chloride, a primary plasticizer, a heat stabilizer, a co-heat stabilizer, a filler, a flame retardant, and a pigment similar to the upper base section 22. However, the composition is different, as shown in Table 4 below.

[0050] In the illustrated embodiment, the intermediate base section 24 includes polyvinyl chloride, a primary plasticizer, a thermal stabilizer, a co-thermal stabilizer, a filler, a flame retardant, and a pigment. The plasticizer is preferably a non-phthalate plasticizer, such as DOTP, DINCH, and a bio-based plasticizer (i.e., octadecanoic acid, 10-chloro-9-methoxy-methyl ester, etc.). The intermediate base section 24 may also include a stabilizer, such as a non-heavy metal content stabilizer. For example, the non-heavy metal content stabilizer may be a calcium / stearate and / or zinc stearate or a calcium / zinc combination complex soap system. The intermediate base section 24 may also include a co-thermal stabilizer, such as epoxidized soybean oil. Fillers may also be added to the intermediate base section 24. For example, limestone may be used as a filler. Flame retardants such as magnesium hydroxide may be used. Pigments such as carbon black or titanium dioxide may also be added.

[0051] Table 4 shows exemplary compositions of the intermediate base section 24 according to the present invention.

[0052] Table 4:

[0053]

[0054]

[0055] In the illustrated embodiment, the intermediate base section 24 comprises two separate material layers, which are then combined with the upper base section 22 and the lower base section 26 during manufacturing, as will be described in more detail below. However, those skilled in the art will appreciate that other designs are possible, including the number of individual layers that make up the lower base section 26.

[0056] As shown, the lower base section 26 is located below the middle base section 24. According to the present invention, the lower base section 26 has a similar composition to the upper base section 22 and the middle base section 24. However, as previously described, the composition of the base layer 20 is changed from a high filler content to a low filler content. This is done by laminating the upper base section 22, the middle base section 24, and the lower base section. Subsequently, the upper base section 26 has a higher polyvinyl chloride content and a higher plasticizer content than the upper base section 22 and the middle base section 24.

[0057] The lower base section 26 has the most polyvinyl chloride and plasticizer. The total content of polyvinyl chloride and plasticizer in the lower base section depends on the thickness of the durable wear layer 14. The higher content of PVC and plasticizer in the lower base section 26 requires a thick durable wear layer 14 to obtain the proper balance of the structure and maintain proper flatness and dimensional stability.

[0058] In the illustrated embodiment, the lower base section 26 includes polyvinyl chloride, primary plasticizer, heat stabilizer, co-heat stabilizer, filler, flame retardant, and pigment similar to the upper base section 22 and the middle base section 24. However, the composition is different, as shown in Table 5 below.

[0059] In the illustrated embodiment, the lower base section 26 includes polyvinyl chloride, a primary plasticizer, a thermal stabilizer, a co-thermal stabilizer, a filler, a flame retardant, and a pigment. The plasticizer is preferably a non-phthalate plasticizer, such as DOTP, DINCH, and a bio-based plasticizer (i.e., octadecanoic acid, 10-chloro-9-methoxy-methyl ester, etc.). The lower base section 26 may also include a stabilizer, such as a non-heavy metal content stabilizer. For example, the non-heavy metal content stabilizer may be a calcium / stearate and / or zinc stearate or a calcium / zinc combination complex soap system. The lower base section 26 may also include a co-thermal stabilizer, such as epoxidized soybean oil. Fillers may also be added to the lower base section 26. For example, limestone may be used as a filler. Flame retardants such as magnesium hydroxide may be used. Pigments such as carbon black or titanium dioxide may also be added.

[0060] Table 5 shows exemplary compositions of lower base segments 26 according to the present invention.

[0061] Table 5:

[0062] Element Recipe (phr) PVC 100 Plasticizers 35-55 Heat Stabilizer 2.0-5.0 Co-stabilizer 4.0-6.0 filler 200-300 Flame retardants 10-20 pigment 0.3-1.0

[0063] In the illustrated embodiment, the lower base section 26 comprises a single layer of material that is then combined with the upper base section 22 and the intermediate base section 24 during manufacturing, as will be described in more detail below. However, those skilled in the art will appreciate that other designs are possible, including multiple layers that comprise the lower base section 26. Figure 4As shown, the lower base section 26 may be milled or stamped to form a pattern on the bottom of the base layer 20 .

[0064] According to the invention, the base layer 20 comprises a glass fiber section 28 which is added inside the base section to increase rigidity. In the embodiment shown, the glass fiber section 28 is located between the upper base section 22 and the intermediate base section to control expansion and contraction of the panel 1 .

[0065] In an exemplary embodiment of the present invention, the glass fiber segment 28 is a layer of glass fiber yarn coated with a polyethylene-based plastisol, and the amount of glass fiber is 10 g / m 2 Up to 25g / m 2 Adding polyethylene-based plastisol allows the glass fiber section 28 to be bonded to other sections of the base layer 20.

[0066] The overall thickness of the base layer 20 may vary. However, in the illustrated embodiment, a base layer 20 having a thickness ranging from 2.8 mm to 4.7 mm is prepared.

[0067] like Figure 3 and 4 As shown, the backing layer 30 is also optional and is made of a single layer of non-slip plastic. The backing layer 30 serves as an anti-slip backing layer. In addition, the backing layer 30 can be provided to balance the top layer 10 and substantially avoid warping of the floor panel 1. Although the thickness of the backing layer 30 can vary, it is suitable to provide a backing layer 30 with a thickness range of 0.2-1.0 mm. In one embodiment of the present invention, the thickness of the backing layer 30 is 0.2-0.3 mm. The backing layer 30 can be made of a variety of materials, including but not limited to polyvinyl chloride, polypropylene, polyolefins, etc. The composition will depend on the intended application of the floor panel 1.

[0068] In the illustrated embodiment, the backing layer 30 is attached to the lower base section 26 and constitutes the bottom of the floor panel 1 so as to stabilize the floor panel 1 from moving when the floor panel is installed. An embossed texture pattern is created to further enhance the anti-slip properties of the floor panel 1. The backing layer 30 may be embossed or the base layer 20 may be embossed and then the backing layer 3020 may be formed on the embossed base layer, as shown.

[0069] In an exemplary embodiment of the present invention, the backing layer 30 has a composition of polyvinyl chloride and a plasticizer. Therefore, the backing layer 30 is quite flexible and conforms to the irregularities of the subfloor.

[0070] like Figure 5-7As shown, the floor panel includes tongue-and-groove connection sections 50, 60. The tongue-and-groove connection sections 50, 60 can be made in various shapes, i.e., although the basic shape should include a narrow groove (groove connection section 60) cut all the way along one side of the floor panel 1, and a protrusion (tongue connection section 50) on the opposite side of the floor panel. The tongue connection section 50 protrudes almost the same as the groove connection section 60, and the groove connection section 60 is made deeper.

[0071] The tongue connection section 50 is a protrusion which is prepared on one side and extends in length beyond the top layer 10 of the floor panel 1. Figure 5 As best shown in FIG. 5 , the tongue connection section 50 has a first guide element 52 formed on a lower section of the tongue connection section 50. The first guide element 52 is circular and has a surface length that is greater than the top surface 53 of the tongue. Thus, the first guide element 52 extends into the body of the adjacent floor panel 1, as shown in FIG. Figure 7 The top surface 53 and tongue end 54 should be shaped to have a flat surface 56 and a tapered surface 58 to promote air flow when connecting adjacent floor panels.

[0072] The groove connection section 60 is formed on the opposite side of the tongue connection section 50. However, the groove connection section 60 extends beyond the peripheral edge of the top layer 10 of the floor panel 1. The second guide element 62 is formed by a recess and has a downwardly concave shape. The dimensions of the first guide element 52 and the second guide element 62 should be approximately the same in radius and length. The groove connection section 60 also includes an upper inclined wall 64 and an inner wall 66.

[0073] The tongue connection section 50 and the groove connection section 60 are formed to have complementary shapes so that when the tongue connection section 50 engages the groove connection section 60 of another floor panel 1, the top surface 53, the tongue end 54 and the first guide element 52 respectively abut against the upper inclined wall 64, the inner wall 66 and the second guide element 62. Since the guide elements 52, 62 have a curved shape, the connected floor panels cannot be pulled apart in the horizontal direction.

[0074] Importantly, the tongue connection section 50 and the groove connection section 60 are formed in the base layer 20. In the exemplary embodiment, the tongue connection section 50 is formed by the fiberglass section 28 and the intermediate base section 24. However, those skilled in the art will appreciate that the tongue connection section 50 may be formed in other sections of the base layer 20.

[0075] Now, an exemplary process for manufacturing the floor panel 1 will be described.

[0076] The wear layer 14 is prepared using an extrusion process and a subsequent four-roll calendering process. Depending on the needs of each formulation, the wear layer may include polyethylene powder, plasticizers, stabilizers, co-stabilizers, lubricants, and UV light stabilizers. These components are added together and then uniformly mixed in a low shear mixer. The mixture is then fed into a kneading extruder, which includes a screw conveyor built into a mixing chamber. The screw continuously rotates away from the discharge end and moves the material into the range of the mixing arm, and then extrudes from the mixing chamber to form a rope-like extrudate. The extrudate is then fed into a planetary extruder. The planetary system may include a hollow cylinder and a main shaft (screw), as well as several satellite screws (spindles) that are harmoniously synchronized with each other to achieve satisfactory mixing and plasticization. The extrudate material is then further processed into a melt through a softer hot melt stage. The melt is then processed and heated to a similar temperature by a calendering roller mill. The shear mixing action on the surface of the calendering roller melts the melt and forms a polymer sheet with a controlled thickness. The thickness of the polymer sheet is controlled by adjusting the distance between the calender rolls. The sheet is then cooled and collected on a reel or cut into sheets, depending on the equipment and process of the downstream operation. For continuous lamination operations, the sheet is produced in roll form and then cut into sizes suitable for the size of the heat press.

[0077] Next, the base layer 20 is prepared, wherein each layer of the upper base segment 22, the middle base segment 24, and the lower base segment 26 is prepared separately. For the sake of brevity, only the preparation of the upper base segment 22 is described. However, those skilled in the art will understand that the same process can be performed using the middle base segment 24 and the lower base segment 26 having different composition ratios, as described above.

[0078] First, with respect to the upper base section 22, polyvinyl chloride, stabilizer and pigment are added together and then uniformly hot mixed using a shear mixer. The remaining constituent elements, such as fillers and flame retardants, are fed into the mixture and then fed into a kneading extruder, and limestone is uniformly mixed. The mixed composition is then fed into a Banbury mixer, which includes two mixing rotors installed in a mixing chamber for rotation, and a slider installed for allowing the mixed compound to enter the mixing chamber through a channel opening. Then after a period of time, when the target temperature is reached, the mixed material is discharged. At this stage, the discharged material is at a temperature of 150-215°C in a hot melt form. The melt is then processed and heated to a similar temperature by a calendering roller mill. The shear mixing action on the surface of the calendering roller melts the melt and forms a polymer sheet with a controlled thickness. The thickness of the upper base section 22 is controlled by adjusting the distance between the calendering rollers.

[0079] The sheet is then cooled and collected on reels or cut into slices.

[0080] A typical process for making LVT includes laminating a base layer 20. The laminate is compressed under heat and pressure. In one embodiment of the present invention, the lamination is a continuous lamination.

[0081] In one exemplary embodiment, an LVT may be prepared by laminating the following sequence together:

[0082] (1) one or more layers of lower base section 26;

[0083] (2) glass fiber section 28;

[0084] (3) one or more intermediate base sections 24; and

[0085] (4) one or more upper base sections 22;

[0086] The laminated sections of the base layer 20 are then cut into slabs. For example, the laminated base layer 20 may be cut into slabs of 1 m x 1 m.

[0087] At this point, the lower base section 26 may be milled or embossed to form a pattern on the bottom of the base layer 20 .

[0088] A typical process for making LVT includes heat pressing the base layer 20 and the top layer 10. The laminate is compressed under heat and pressure. In one embodiment of the present invention, the lamination is a continuous lamination.

[0089] In one exemplary embodiment, the LVT is then prepared by heat pressing the laminate base layer 20 with the backing layer 30 and the top layer 10 together in the following order:

[0090] (1) wear-resistant layer 14;

[0091] (2) Printing layer 16;

[0092] (3) base layer 20; and

[0093] (4) Backing layer 30.

[0094] The press plate is placed on top of the above assembled stack. The stack is then heated to about 130°C-150°C and a pressure of about 3-5 MPa is applied by the press plate for about 20-30 minutes. The press is then cooled to 30°C-50°C and the LVT is removed.

[0095] Furthermore, the floor panel 1 is then cooled for several hours before a UV curing coating system is applied on the surface of the product to form a thin coating 12. The coating material is usually formulated with functional monomers and photoinitiators and other substances together with polyurethane acrylate oligomers, which cure the coating under appropriate UV energy and form a hard three-dimensional cross-linked surface. The UV coating provides the floor with excellent surface properties such as stain resistance and chemical resistance, appearance and gloss retention, scratch resistance and wear resistance, etc.

[0096] After coating, the product is further processed by annealing to release internal stresses from previous processes. Without proper annealing, the dimensional stability of the product may be affected. Further processes may be carried out after annealing, such as extrusion, punching, forming to form tongue and groove locking profiles, and inspection before packaging into cartons, as well as processes well known in the industry.

[0097] The foregoing illustrates some possibilities for practicing the present invention. Many other embodiments and fields for the LVT of the present invention are possible and within the scope and spirit of the present invention. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the present invention is given by the appended claims and all equivalents thereof.

Claims

1. A floor panel composition comprising: Top floor; A base layer having a first base section, a second base and a glass fiber section, characterized in that: The first base section includes a first composition of polyvinyl chloride, a filler, and a plasticizer; The second base segment includes a second composition having a higher content of polyethylene and plasticizer than the first composition of polyvinyl chloride, filler, and plasticizer; and The fiberglass section is located between the first base section and the second base section.

2. The floor panel according to claim 1, further comprising, A protrusion is formed on one side of the base layer and extends outwardly beyond the top layer.

3. The floor panel according to claim 2, wherein The amount of filler of the first base section is 300 parts per 100 parts of polyvinyl chloride to 400 parts per 100 parts of polyvinyl chloride.

4. The floor panel according to claim 3, wherein The amount of plasticizer in the first base section is from 25 parts per 100 parts of polyvinyl chloride to 35 parts per 100 parts of polyvinyl chloride.

5. The floor panel according to claim 4, wherein The first base section also includes a heat stabilizer in an amount of 2.0 parts per 100 parts of polyvinyl chloride to 5.0 parts per 100 parts of polyvinyl chloride.

6. The floor panel according to claim 5, wherein The first base section also includes a co-thermal stabilizer in an amount of 4.0 parts per 100 parts of polyvinyl chloride to 6.0 parts per 100 parts of polyvinyl chloride.

7. The floor panel according to claim 6, wherein The first base section also includes a flame retardant in an amount of 10.0 parts per 100 parts of polyvinyl chloride to 20.0 parts per 100 parts of polyvinyl chloride.

8. The floor panel according to claim 7, wherein The first base section also includes a pigment in an amount of 0.3 parts per 100 parts of polyvinyl chloride to 1.0 parts per 100 parts of polyvinyl chloride.

9. The floor panel according to claim 4, wherein The amount of filler of the second base section is 250 parts per 100 parts of polyvinyl chloride to 350 parts per 100 parts of polyvinyl chloride.

10. The floor panel according to claim 9, wherein The amount of plasticizer in the second base section is from 28 parts per 100 parts of polyvinyl chloride to 40 parts per 100 parts of polyvinyl chloride.

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