Flooring and floor panels and vehicles including same

Abstract

Flooring and floor panels are described that include the multi-layer tape. The multi-layer tape can include two or more layers, at least one of which can include a unidirectional orientation of the fibers. In some configurations, the panels can include a tape having multiple layers, each layer of the tape including a unidirectional orientation of the fibers that can be the same or different. Vehicles and other devices that include the panels are also described.

Description

[Technical field]

[0001] Priority Application This application is related to and claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 134,117, filed January 5, 2021, and U.S. Provisional Patent Application No. 63 / 162,066, filed March 17, 2021. The entire disclosure of each of these applications is incorporated herein by reference.

[0002] Technical Field Certain configurations described herein relate to flooring and floor panels. In some examples, the flooring can be used in recreational vehicles or architectural applications.

[0003] background Flooring is often subjected to large forces and stresses in addition to water, dirt and other materials. Existing flooring is typically manufactured using wood-based materials. When wood-based flooring is exposed to water, dirt and large impact forces, the flooring is often damaged.

[0004] overview DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Certain aspects, configurations, embodiments and examples of flooring and floor panels that can be used in recreational vehicles or in architectural or other applications are described.

[0005] In one aspect, the floor panel comprises a tape layer, a reinforced thermoplastic layer, a spacer layer, and a support layer. In certain embodiments, the tape comprises a plurality of fibrous layers bonded together, at least two fibrous layers of the tape comprise a unidirectional fiber orientation, and the tape comprises at least two fibrous layers having different unidirectional fiber orientations. In some embodiments, the reinforced thermoplastic layer is bonded to a first surface of the tape at a first surface of the lightweight reinforced thermoplastic layer, the reinforced thermoplastic layer comprises an open cell web formed by the reinforcement material held in place by the thermoplastic material. In other embodiments, a spacer layer, e.g., a foam layer, is bonded to a second surface of the reinforced thermoplastic layer at a first surface of the foam layer. In some configurations, the support layer is bonded to the second surface of the foam layer.

[0006] In certain embodiments, each fiber layer of the tape includes a binder to hold the fibers in one direction, and the tape includes an outer layer, such as a film, frit, scrim, etc., on a first surface of the tape and a second surface of the tape. In some embodiments, the support layer includes a metal. For example, the support layer can include one or more of galvanized steel, aluminum, or other metal-containing materials. In other examples, the support layer can include a reinforced thermoplastic layer, a non-metallic layer, a plastic layer, or a tape layer. In some embodiments, the support layer includes a second reinforced thermoplastic layer comprising an open-celled web formed by a reinforcement material held in place by a thermoplastic material. In other embodiments, the floor panel includes a cover layer disposed on the tape layer. In some examples, the cover layer includes one or more of a scrim, a cloth, a plastic, a laminate, wood, or a combination thereof.

[0007] In certain embodiments, the tape is a bi-layer tape having two individual fibrous layers bonded together. For example, the tape can comprise a first fibrous layer bonded to a second fibrous layer, with the unidirectional fiber orientation of the first fibrous layer being orthogonal to the unidirectional fiber orientation of the second fibrous layer.

[0008] In other embodiments, the tape is a four-ply tape having four individual fiber layers bonded together. For example, a first fiber layer is bonded to a second fiber layer, and the unidirectional fiber orientation of the first fiber layer is orthogonal to the unidirectional fiber orientation of the second fiber layer. In other embodiments, a third fiber layer of the tape is bonded to a second fiber layer of the tape, and the unidirectional fiber orientation of the third fiber layer is orthogonal to the unidirectional fiber orientation of the second fiber layer. In further embodiments, a fourth fiber layer of the tape is bonded to a third fiber layer of the tape, and the unidirectional fiber orientation of the fourth fiber layer is orthogonal to the unidirectional fiber orientation of the third fiber layer. In some examples, a fourth fiber layer of the tape is bonded to a third fiber layer of the tape, and the unidirectional fiber orientation of the fourth fiber layer is parallel to the unidirectional fiber orientation of the third fiber layer.

[0009] In other embodiments, the third fibrous layer of the tape is bonded to the second fibrous layer of the tape, and the unidirectional fiber orientation of the third fibrous layer is parallel to the unidirectional fiber orientation of the second fibrous layer. In some examples, the fourth fibrous layer of the tape is bonded to the third fibrous layer of the tape, and the unidirectional fiber orientation of the fourth fibrous layer is perpendicular to the unidirectional fiber orientation of the third fibrous layer. In other embodiments, the fourth fibrous layer of the tape is bonded to the third fibrous layer of the tape, and the unidirectional fiber orientation of the fourth fibrous layer is parallel to the unidirectional fiber orientation of the third fibrous layer.

[0010] In certain configurations, the tape is a six-ply tape having six individual fiber layers bonded together. In other embodiments, a first fiber layer of the tape is bonded to a second fiber layer of the tape, and the unidirectional fiber orientation of the first fiber layer is perpendicular to the unidirectional fiber orientation of the second fiber layer. In other embodiments, a first fiber layer of the tape is bonded to a second fiber layer of the tape, and the unidirectional fiber orientation of the first fiber layer is parallel to the unidirectional fiber orientation of the second fiber layer.

[0011] In certain embodiments, the tape comprises 2-6 individual fiber layers each with unidirectional fiber orientation, the reinforced thermoplastic layer comprises polyolefin and inorganic reinforcing fibers, the spacer layer is a foam layer comprising expandable polystyrene foam, and the support layer comprises galvanized steel.

[0012] In other embodiments, the tape comprises 2-6 individual fiber layers, each with a unidirectional fiber orientation. The reinforced thermoplastic layer comprises polypropylene and glass reinforcing fibers. For example, the reinforced thermoplastic layer comprises 45-60 wt. % polyolefin and the remaining percentage of inorganic reinforcing fibers, so that the weight percent of polyolefin and the weight percent of inorganic reinforcing fibers together comprise 100 wt. % in the reinforced thermoplastic layer. The spacer layer is a foam layer comprising expandable polystyrene foam, and the support layer comprises galvanized steel. In some embodiments, the polyolefin is polypropylene or polyethylene. In further embodiments, the inorganic reinforcing fibers are glass reinforcing fibers.

[0013] In another embodiment, the tape comprises 2-6 individual fiber layers each with a unidirectional fiber orientation. The reinforced thermoplastic layer comprises polypropylene and glass reinforcing fibers, and the reinforced thermoplastic layer comprises 45-60 wt% polyolefin and the remaining percentage of inorganic reinforcing fibers, so that the weight percent of polyolefin and the weight percent of inorganic reinforcing fibers together account for 100 wt% in the reinforced thermoplastic layer. The spacer layer is a foam layer comprising one or more of expandable polystyrene foam, polyurethane foam, or extruded polystyrene foam, and the support layer comprises a second reinforced thermoplastic layer comprising an open-celled web formed by a reinforcing material held in place by a thermoplastic material. In some examples, the polyolefin is polypropylene or polyethylene. In other examples, the inorganic reinforcing fibers are glass reinforcing fibers. In certain examples, the thermoplastic material of the second reinforced thermoplastic layer comprises a polyolefin. In some embodiments, the reinforcing material of the second reinforced thermoplastic layer comprises inorganic reinforcing fibers, such as glass fibers. In other configurations, the thermoplastic material of the second reinforced thermoplastic layer comprises a polyolefin, and the reinforcing material of the second reinforced thermoplastic layer comprises inorganic reinforcing fibers. The polyolefin is present in the second reinforced thermoplastic layer at 45-60 wt %, and the inorganic reinforcing fibers are present in the second reinforced thermoplastic layer at the remaining wt %, so that the weight % of the polyolefin and the weight % of the inorganic reinforcing fibers together account for 100 wt % in the second reinforced thermoplastic layer.

[0014] In another aspect, the vehicle floor comprises a first floor panel and a second floor panel, which can abut each other or overlap as needed. In certain embodiments, the first floor panel comprises a tape comprising a plurality of fibrous layers bonded together, each fibrous layer of the tape comprising a unidirectional orientation of the fibers, and the tape comprising at least two fibrous layers having different fiber orientations. The first floor panel can also comprise a reinforced thermoplastic layer bonded to a first surface of the tape at a first surface of the lightweight reinforced thermoplastic layer, the reinforced thermoplastic layer comprising an open-celled web formed by a reinforcement material held in place by a thermoplastic material, and a spacer layer bonded to a second surface of the reinforced thermoplastic layer at a first surface of the spacer layer. The first floor panel can also include a support layer bonded to the second surface of the spacer layer. In some configurations, the second floor panel comprises a tape comprising a plurality of fibrous layers bonded together, each fibrous layer of the tape comprising a unidirectional orientation of the fibers, and the tape comprising at least two fibrous layers having different fiber orientations. The second floor panel may also include a reinforced thermoplastic layer bonded to the first surface of the tape at the first surface of the lightweight reinforced thermoplastic layer, the reinforced thermoplastic layer comprising an open cell web formed by the reinforcement material held in place by the thermoplastic material. The second floor panel may also include a spacer layer bonded to the second surface of the reinforced thermoplastic layer at the first surface of the spacer layer. The second floor panel may also include a support layer bonded to the second surface of the spacer layer. In a particular arrangement, the first floor panel may be positioned adjacent to the second floor panel, and the cover layer may be positioned over the adjacently positioned first and second floor panels.

[0015] In certain embodiments, the vehicle floor includes a third floor panel disposed adjacent to the second floor panel. If necessary, a covering layer is disposed on the adjacently disposed first and second floor panels, and the adjacently disposed second and third floor panels. For example, a layer of material can be disposed on two or more floor panels that are abutted against each other or otherwise disposed adjacent to each other.

[0016] In some examples, the tapes of each of the first and second floor panels are independently selected from tapes with two, four, or six individual layers, with at least one layer of the tape having a unidirectional fiber orientation. In certain embodiments, the tapes of each of the first and second floor panels are independently selected from tapes with two, three, four, five, or six (or more) individual layers, with at least two layers of the tape having a unidirectional fiber orientation. In other embodiments, the tapes of each of the first and second floor panels are independently selected from tapes with two, three, four, five, or six (or more) individual layers, with each layer of the tape having a unidirectional fiber orientation.

[0017] In some examples, the tape of each of the first floor panel and the second floor panel includes a scrim on each surface of the tape.

[0018] In another aspect, a vehicle, e.g., a recreational vehicle, comprises a roof, side walls coupled to the roof, and a floor coupled to the side walls to provide an interior space within the vehicle. In some embodiments, the floor of the vehicle comprises a first panel and, optionally, a second and / or third floor panel or a plurality of floor panels, as described herein. In some embodiments, the vehicle floor can include a covering layer covering the first and second floor panels (and any other floor panels present). In some examples, the tapes of each of the first and second floor panels are independently selected from tapes comprising two, four, or six individual layers, at least one layer of the tape comprising a unidirectional fiber orientation. In other examples, the tapes of each of the first and second floor panels are independently selected from tapes comprising two, three, four, five, or six (or more) individual layers, at least two layers of the tape comprising a unidirectional fiber orientation, or each layer of the tape comprising a unidirectional fiber orientation.

[0019] In a further aspect, a kit for producing a floor includes a reinforced thermoplastic layer comprising an open cell web formed by a reinforcing material held in place by a thermoplastic material, and written or electronic instructions for bonding the reinforced thermoplastic layer to a tape layer, a spacer layer, and a support layer to provide the floor.

[0020] In certain embodiments, the kit may also include one or more of a tape, a spacer layer, and a support layer. Alternatively, the kit may include materials for forming one or more of these other layers. For example, the kit may include materials for forming a foam layer as a spacer layer, for example, the kit may include materials for forming an expanded foam material, an extruded foam, or a cast foam.

[0021] Further aspects, configurations, embodiments and examples are described below. Brief description of some views of the drawing To facilitate a better understanding of the technology described herein with reference to the accompanying drawings, certain specific examples are set forth below. [Brief description of the drawings]

[0022] [Figure 1] 1 is a simplified diagram illustrating one configuration of a floor panel or flooring according to some embodiments. [Figure 2A] 1A-1C illustrate two plies or layers of tape, according to some examples. [Figure 2B] 1A-1C illustrate two plies or layers of tape, according to some examples. [Figure 2C] 1A-1C illustrate two plies or layers of tape, according to some examples. [Figure 2D] 1A-1C illustrate two plies or layers of tape, according to some examples. [Figure 3A] 1A-1C illustrate three plies or layers of tape, according to some examples. [Figure 3B] 1A-1C illustrate three plies or layers of tape, according to some examples. [Figure 3C] 1A-1C illustrate three plies or layers of tape, according to some examples. [Figure 3D] 1A-1C illustrate three plies or layers of tape, according to some examples. [Figure 3E] 1A-1C illustrate three plies or layers of tape, according to some examples. [Figure 4] FIG. 1 shows an outer layer on a tape according to a particular configuration. [Figure 5A] FIG. 1 illustrates a four-ply tape according to some embodiments. [Figure 5B] FIG. 1 illustrates a four-ply tape according to some embodiments. [Figure 6A] FIG. 1 illustrates a six-ply tape according to certain embodiments. [Figure 6B] FIG. 1 illustrates a six-ply tape according to certain embodiments. [Figure 7A] 1A-1C illustrate different tape plies or layers according to some embodiments. [Figure 7B] 1A-1C illustrate different tape plies or layers according to some embodiments. [Figure 8] 1 illustrates an adhesive layer between plies or layers of tape, according to certain examples. [Figure 9] FIG. 2 illustrates a tape layer, a reinforced thermoplastic layer, and a spacer layer according to a particular configuration. [Figure 10] FIG. 2 illustrates a tape layer, a reinforced thermoplastic layer, a spacer layer, and a support layer according to a particular configuration. [Figure 11] FIG. 2 illustrates a tape layer, two reinforced thermoplastic layers, a spacer layer, and a support layer in a particular configuration. [Figure 12A] FIG. 1 illustrates floor panels placed adjacent to one another according to some embodiments. [Figure 12B] FIG. 1 illustrates floor panels placed adjacent to one another according to some embodiments. [Figure 13] 1 is an illustration of a recreational vehicle, according to some embodiments. [Figure 14] FIG. 1 illustrates a tested floor panel according to certain embodiments. [Figure 15] 1 is a graph illustrating Janka heel indentation results for various materials, in accordance with certain embodiments. [Figure 16] 1 is a graph illustrating bed weights of various materials, according to certain embodiments. [Figure 17] 1A-1C illustrate different layouts of various layers described herein, according to some embodiments. [Figure 18] 1A-1C illustrate different layouts of various layers described herein, according to some embodiments. [Figure 19] 1 is a graph showing #10 screw retention for the two panels tested and the lauan wood panel benchmark. [Figure 20] 1 is a graph showing knee load deflection measurements of the produced test panels and lauan wood panels. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Those of ordinary skill in the art, given the benefit of this disclosure, will recognize that certain layers or plies may be intentionally enlarged or otherwise distorted to facilitate a more user-friendly description of the technology. No specific thicknesses, dimensions, or materials are intended to be required or implied unless indicated in the following description.

[0024] Detailed Description Given the benefit of this description, it will be recognized by those skilled in the art that the different layers shown in the floor panels and floorings are not necessarily shown to scale. No material is intended to be required for any one layer unless specifically indicated in the description related to its particular configuration. The thickness, arrangement and end use of the flooring and floor panels may vary. The different plies may be configured as single plies or multiple plies, for example, there may be two or more plies that together constitute a single ply tape. Furthermore, the tape may include multiple plies, each ply having a similar or different fiber orientation to the other plies of the tape.

[0025] In certain embodiments, the floor panels and articles described herein can be used in place of wood panels. For example, the floor panels and articles described herein can be impact resistant, rot and mildew resistant, and can provide similar sized panels, e.g., 4' x 8', at a lower overall weight compared to wood panels. Although certain examples are described in relation to floors and floor panels, the panels can instead be used as boats, hunting blinds, large trucks, interior or exterior decks, planks for utility trailers, or in other applications where wood panels or planks are commonly used.

[0026] In certain embodiments, the floor panel or flooring may include a multi-layer composite that may provide one or more of impact resistance, noise reduction, or other desired properties. In some embodiments, at least one layer of the floor panel or flooring includes a multi-ply or multi-layer tape having fiber reinforcement in each ply of the tape. For example, the floor panel or flooring may include multiple individual plies, each ply comprising a unidirectional arrangement of fibers or fiber bundles. Adjacent tape plies or layers may have fibers in the same or different orientations. Additional layers or materials may be present between the tape layers or on the outer surface of the multi-ply tape. The exact number of plies present in a tape layer may vary from 2-12, more specifically 2-10 or 2-8 or 2-6, for example, 2, 4, 5, 6, 7, 8, 9, 10, 11, 12 or more individual plies or layers may be present in the tape. In some configurations, each ply may comprise the same thickness, while in other instances, different plies may have different thicknesses. Similarly, the chemical composition of each ply of the tape may be the same or different. In some instances, the fiber composition present in each tape layer may be the same, while in other configurations, at least one ply of the tape includes fibers of different composition. The fibers present in the plies or layers of the tape may be chemically treated, if desired, to impart desired properties to the tape layer. Given the benefit of this disclosure, it will be recognized by those skilled in the art that each layer of the tape need not include fibers. For example, if there are four, six, or more than three layers of tape, at least two layers of the tape may include one fiber orientation, but not all layers of the tape need have a particular fiber orientation or even include fibers. In some cases, at least one layer of the multi-layer tape may be fiber-free.

[0027] In some examples, each ply or layer of tape generally includes a binder and fibers arranged in one direction. The binder can hold the fibers in a desired orientation. For example, the binder can hold the fibers such that individual fibers or fiber bundles are parallel to another fiber or fiber bundle. The fibers present in the tape can typically be present as fiber bundles, with each fiber bundle being parallel to other fiber bundles present in the ply. For reference, if the fiber bundles are oriented at 0 degrees, the fibers / fiber bundles can be oriented parallel to the machine direction present when the underlying lightweight reinforced thermoplastic (LWRT) layer is manufactured. If the fiber bundles are oriented at 90 degrees, the fiber bundles can be oriented parallel to the cross direction present when the underlying lightweight reinforced thermoplastic (LWRT) layer is manufactured. In some cases, the fiber bundles in the ply can be oriented at angles greater than 0 degrees and less than 90 degrees. Diagrams of different fiber bundle angles are described in more detail below. In certain embodiments, the presence of the multi-ply tape can impart impact resistance to a flooring or floor panel including the multi-ply tape. For example, the impact resistance of a floor panel or flooring including multi-ply tape as one layer can be 230N or more as tested by ASTM D1037-12. In another example, the impact resistance of a floor panel or flooring including multi-ply tape can be increased at a thinner overall thickness compared to plywood flooring. For example, a floor panel described herein having an overall thickness of 6mm to 7mm can have approximately the same impact resistance as a plywood flooring having a thickness of about 10mm. In addition to improved impact resistance at thinner thicknesses, the flooring and floor panels described herein can also be resistant to rot, moisture, mold and mildew.

[0028] In certain embodiments, the multi-ply tapes described herein may be used in combination with a lightweight reinforced thermoplastic layer (LWRT), also referred to herein simply as a reinforced thermoplastic layer. In FIG. 1, a floor panel or flooring 100 is shown including a LWRT layer 110 bonded to a multi-ply tape 120. The LWRT layer 110 may include a thermoplastic material and a reinforcing material. For example, the LWRT layer 110 may include an open-celled web formed from reinforcing fibers held in place by a thermoplastic material. The LWRT layer 110 is typically highly porous and includes a significant amount of open-celled structure such that voids exist within the layer 110. In some examples, layer 110 may be 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-80%, 20-95%, 20-95%, 20-10 ... , 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95%, 70-80%, 70-90%, 70-95%, 80-90%, 80-95%, or any exemplary value within these exemplary ranges.

[0029] In certain embodiments, the thermoplastic materials used to form layer 110 may include one or more of polyolefins (e.g., one or more of polyethylene, polypropylene, etc.), polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as blends of these materials with each other or with other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4 phenylene) compounds commercially available as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons and silicones, as well as copolymers, alloys, blends of these materials with each other or with other polymeric materials. The thermoplastic materials used to form layer 110 can be used in powder form, resin form, rosin form, particle form, fiber form, or other suitable form. Exemplary thermoplastic materials in various forms are described herein and also in, for example, U.S. Patent Application Publication No. 20130244528 and U.S. Patent Application Publication No. 20120065283. The exact amount of thermoplastic material present in layer 110 may vary, with exemplary amounts ranging from about 20% by weight to about 80% by weight, such as 30-70% by weight or 35-65% by weight, based on the total weight of LWRT layer 110. One of ordinary skill in the art will recognize that the weight percentages of all materials used in layer 110 add up to 100% by weight.

[0030] In other embodiments, the reinforcing material of layer 110 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers, such as para- and meta-aramid fibers, nylon fibers, polyester fibers, high melt flow index resins suitable for use as fibers (e.g., fibers with a melt flow index (MFI) or greater than 100 g / 10 min), mineral fibers, such as basalt, mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated prior to use to provide desired functional groups or impart other physical properties to the fibers, e.g., chemically treated to allow reaction with thermoplastic materials, lofting agents, or other materials. The fiber content in layer 110 may independently be from about 20% to about 90% of the weight of layer 110, more particularly from about 30% to about 70% of the weight of layer 110. The particular size and / or orientation of the fibers used may depend at least in part on the thermoplastic material used and / or the desired properties of the LWRT layer 110. In one non-limiting example, the fibers dispersed within the thermoplastic material and optionally other additives to provide layer 110 can generally have a diameter greater than about 5 microns, more specifically from about 2 microns to about 22 microns, and a length of from about 5 mm to about 200 mm, more specifically, the fiber diameter may be from about 5 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm. The fibers within layer 110 typically have a random orientation.

[0031] In certain embodiments, other additives may also be present in layer 110. For example, lofting agents, flame retardants, colorants, smoke suppressants, surfactants, foams or other materials may be present. In some examples, layer 110 may be a substantially halogen-free or halogen-free layer to meet the limits of hazardous materials requirements for a particular application. In other examples, layer 110 may include a halogenated flame retardant, such as a halogenated flame retardant containing one or more of F, Cl, Br, I, and At, or a compound containing such a halogen, such as tetrabromobisphenol A polycarbonate or a mono-, di-, tri- or tetra-halo polycarbonate. In some examples, the thermoplastic material used in layer 110 may include one or more halogens to impart some degree of flame retardancy without the addition of a separate flame retardant. If a halogenated flame retardant is present, the flame retardant is desirably present in a flame retardant amount that may vary depending on other components present. For example, the halogenated flame retardant may be present at about 0.1% to about 15% by weight (based on the weight of layer 110), more specifically, about 1% to about 13% by weight, e.g., about 5% to about 13% by weight, based on the weight of layer 110. If desired, two different halogenated flame retardants may be added or present in layer 110. In other examples, a non-halogenated flame retardant may be added, such as a flame retardant including one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogenated flame retardant may include a phosphorylated material, so that layer 110 may be more environmentally friendly. When a non-halogenated or substantially halogen-free flame retardant is present, the flame retardant is desirably present in a flame retardant amount that may vary depending on other components present. For example, the substantially halogen-free flame retardant may be present at about 0.1% to about 15% by weight (based on the weight of layer 110), more specifically, at about 1% to about 13% by weight, such as about 5% to about 13% by weight, based on the weight of layer 110. If desired, two different substantially halogen-free flame retardants may be added to one or more of the LWRT layers described herein.In certain cases, one or more of the LWRT layers described herein may include one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. When two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount that may vary depending on the other components present. For example, the total weight of the flame retardants present may be from about 0.1% to about 20% by weight (based on the weight of the layer 110), more specifically, from about 1% to about 15% by weight, e.g., from about 2% to about 14% by weight, based on the weight of the layer 110. The flame retardants used in the LWRT layers described herein may be added to a mixture including the thermoplastic material and the fibers (before processing the mixture on a wire screen or other processing component) or may be added after the layer 110 is formed. In some examples, the flame retardant material may include one or more of an expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0032] In certain embodiments, the multi-ply tape layer 120 may include two or more individual plies with different fiber orientations. For example, with reference to Figures 2A and 2B, a top view of a two-ply tape is shown including a first ply 210 with a first fiber orientation and a second ply 210 with a second ply orientation. For illustrative purposes, a portion of the first ply 210 is removed in Figure 2B to allow for observation of the underlying fibers within the first ply 210. The first ply 210 has a first fiber orientation oriented at 90 degrees relative to the fiber orientation of the second ply 220. For example, the fibers of the first ply 210 may be oriented at 0 degrees and the fibers of the second ply 220 may be oriented at 90 degrees. These orientations are exemplary and other angles may exist. For example, with reference to Figure 2C, a ply 230 is shown having a 45 degree fiber orientation. Ply 230 may instead have a different angle relative to the zero degree fibers in ply 210, for example, an orientation of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85 degrees, or any angle between these values. Although the fiber orientations of plies 220 and 230 are all shown as being substantially parallel to one another, the fiber orientations may vary across the surface of the tape, if desired. Referring to Figure 2D, ply 250 is shown including +45 degree and -45 degree fibers in different regions along the ply.

[0033] In certain examples, the tapes described herein may include three or more different plies or layers. With reference to FIG. 3A, a three-ply tape 300 is shown that includes a 0 / 90 / 0 fiber orientation (top to bottom), with portions of plies 312 and 314 removed to allow the underlying plies to be seen. For example, first ply 312 includes a 0 degree orientation, second ply 314 includes a 90 degree fiber orientation, and third ply 316 includes a 0 degree fiber orientation. This ply orientation can be varied as desired. For example, FIG. 3B shows a 0 / 0 / 90 arrangement where plies 322, 324 have a 0 degree fiber orientation and ply 326 has a 90 degree fiber orientation. FIG. 3C shows a 90 / 0 / 0 arrangement where ply 332 includes a 90 degree fiber orientation and plies 334, 336 include a 0 degree fiber orientation. Figure 3D shows a 0 / 90 / 90 arrangement where ply 342 has a 0 degree fiber arrangement and plies 344, 346 have a 90 degree fiber arrangement. Figure 3E shows a 90 / 90 / 0 arrangement where plies 352, 354 have a 90 degree fiber arrangement and ply 356 has a 0 degree fiber arrangement. Other arrangements are possible. For example, a three-ply tape can have a 0 / 0 / 0 or 90 / 90 / 90 fiber arrangement as desired.

[0034] In some embodiments, a multi-ply tape can include an outer layer on each surface of the tape layers. For example, referring to FIG. 4, a tape 400 includes three plies (collectively 410), a first outer layer 420, and an optional second outer layer 430. In some examples, the second outer layer 430 can be omitted if desired. The outer layers 420, 430 can act to hold the binder material within the various plies. For example, the outer layers 420, 430 can be a film, a scrim, or other material that can act to promote adhesion of the tape to other layers. The outer layers 420, 430 can be the same or different. In some embodiments, the outer layers 420, 430 can each independently be a polyolefin film, a cloth, a scrim (woven or nonwoven), a flim (film + scrim), or other layers. The outer layers 420, 430 can include fibers or be fiber-free. For example, in certain configurations, the outer layers 420, 430 may each be a fiber-based scrim that may include at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers. In other configurations, the layers 420, 430 may each be a scrim that includes materials or fibers made from one or more of the thermoplastic materials described above in connection with the LWRT layers. In other examples, the outer layers may be printed and / or include an antimicrobial material or coating.

[0035] In certain embodiments, the tapes described herein may comprise more than three plies or layers. For example, the tapes may comprise 4, 5, 6, 7, 8, 9, 10, 11, 12 or more individual plies. As described herein, each ply may have a unidirectional fiber orientation or arrangement, and adjacent plies may have the same fiber arrangement, e.g., 0 / 0 or 90 / 90, or may have different fiber arrangements, e.g., 0 / 90 or 90 / 0. Some illustrative examples of tapes with more than three plies are shown in Figures 5A and 5B. In Figure 5A, tape 500 comprises plies 512, 514, 516, and 518, each having a 0 / 90 / 0 / 90 arrangement. In Figure 5B, tape 550 comprises plies 552, 554, 556, and 558, each having a 0 / 90 / 90 / 0 arrangement. It will be recognized by those of skill in the art, given the benefit of this disclosure, that other arrangements of different plies are also possible. For example, in a four-ply, there can be a 90 / 0 / 0 / 90 arrangement of fibers in different plies. Other fiber arrangements in a four-ply tape include, but are not limited to, 90 / 0 / 90 / 0, 90 / 90 / 0 / 0, 90 / 0 / 0 / 90, 0 / 0 / 90 / 90, 0 / 90 / 90 / 90, 90 / 0 / 90 / 90, 90 / 90 / 90 / 0, 0 / 0 / 0 / 90, 0 / 0 / 90 / 0, 0 / 90 / 0 / 0, and 90 / 0 / 0 / 0. If desired, all plies can have the same fiber arrangement, e.g., 0 / 0 / 0 / 0 or 90 / 90 / 90 / 90. As discussed above in connection with three-ply tapes, tapes having four plies can include an outer layer, e.g., a film, scrim, flim, etc., which can function, for example, to promote adhesion of the tape to other layers.

[0036] In certain embodiments, the tape may include 5 plies, 6 plies (FIGS. 6A and 6B), 7 plies, 8 plies, or more than 8 plies. For illustrative purposes, a 6-ply tape is shown in FIGS. 6A and 6B. With reference to FIG. 6A, a 6-ply tape 600 includes plies 612, 614, 616, 618, 620, and 622, each having a fiber arrangement of 0 / 90 / 0 / 90 / 0 / 90. With reference to FIG. 6B, a 6-ply tape 650 includes plies 652, 654, 656, 658, 660, and 662, each having a fiber arrangement of 90 / 0 / 90 / 0 / 90 / 0. If a 5-ply tape is present, the fiber arrangement may be, for example, 0 / 90 / 90 / 0 / 0 or other arrangement. If a 7-ply tape is present, a fiber arrangement of 0 / 90 / 0 / 90 / 0 / 90 / 0 or other fiber arrangement may be present. If an 8-ply tape is present, there may be a fiber arrangement of 0 / 90 / 0 / 90 / 0 / 90 / 0 / 90, or other fiber arrangements. The fiber orientations of the different tapes shown in the figures are merely exemplary, and many different fiber arrangements are possible. For example, in a 6-ply tape, the different layers may have a 0 / 90 / 90 / 90 / 90 / 0 or 0 / 90 / 0 / 0 / 90 / 0 arrangement, as desired.

[0037] In certain embodiments, the thickness of each ply of the tape may be the same or different from the other plies of the tape. FIG. 7A shows a four-ply tape 710 in which each ply 712, 714, 716, and 718 has the same thickness. FIG. 7B shows a four-ply tape 750 in which plies 752, 754, and 758 have the same thickness and ply 756 has an increased thickness. The exact thickness of each ply may vary, for example, from about 0.05 mm (about 2 mils) to about 0.5 mm (about 20 mils), more specifically from about 0.1 mm (about 4 mils) to about 0.25 mm (about 10 mils) or from about 0.3 mm (about 12 mils) to about 0.35 mm (about 14 mils). After combining different plies, the thickness of the entire tape may be changed. In some configurations, the total tape thickness of a two-ply tape may be from about 0.4 mm to about 0.8 mm. The total thickness of a four-ply tape may vary from about 0.8 mm to about 1.6 mm. The total thickness of the 6-ply tape may vary from about 1.2 mm to about 2.4 mm. The total thickness of the 8-ply tape may vary from about 1.6 mm to about 3.2 mm.

[0038] In certain embodiments, different plies of the tape can be bonded to each other via an adhesive layer. For example, referring to FIG. 8, a two-ply tape 800 is shown comprising a first ply 812 bonded to a second ply 814 via an adhesive layer 816. The adhesive layer 816 may comprise a thermoplastic or thermosetting material or both. In some embodiments, the adhesive layer 816 may comprise a material present in a binder used in one or more of the plies 812, 814. For example, the binder of the plies 812, 814 may be a thermoplastic material and the same thermoplastic material may be present in the adhesive layer 816. In some embodiments, the adhesive layer 816 may comprise one or more of a polyolefin, polyurethane, polyamide, copolyamide, or combinations thereof. For example, the adhesive layer 816 may comprise polyethylene, polypropylene, or combinations and copolymers thereof. There is sufficient adhesive to allow the plies 812, 814 to remain bonded to each other with zero to minimal delamination when the flooring or floor panel is in use. Optionally, an adhesive layer may be present between each ply or layer of a multi-ply or multi-layer tape.

[0039] In certain embodiments, the multi-ply tape layer 120 and the LWRT layer 110 may be used in combination with a foam or other spacer layer. For example, referring to FIG. 9, a spacer layer 910, such as a foam layer, may be bonded to the LWRT layer 110. The spacer layer 910 may be a honeycomb layer or a layer having an open structure. In some examples, the layer 910 may include expanded polystyrene foam, extruded polystyrene foam, polyurethane foam, or other foam. Alternatively, the layer 910 may have a honeycomb structure manufactured from polyurethane, cellulose, or other materials. The spacer layer 910 may support the flooring or floor panel and may also provide some noise reduction. Although shown here, the layer 910 may be bonded to the LWRT layer 110 via an adhesive layer. Similarly, the LWRT layer 110 may be bonded to the tape layer 120 via an adhesive layer. Exemplary adhesive materials include, but are not limited to, thermoplastic adhesives and thermosetting adhesives. For example, the adhesive layer may include polyolefins, polyurethanes, polyamides, copolyamides, or combinations thereof. The exact thickness and weight of the spacer layer 910 can vary. In some embodiments, the thickness of the spacer layer 910 can be from about 0.5 cm to about 5 cm, more specifically, from about 1 cm to about 4 cm or from about 3 cm to about 4 cm. If the spacer layer 910 comprises a foam, the density of the foam may vary from about 1 pound per cubic foot (pcf) to about 5 pcf, more specifically, from about 2 pcf to about 4 pcf or from 2 pcf to 3 pcf. If desired, the spacer layer 910 can include additives, particles, fibers, powders or other materials.

[0040] In some configurations, one or more support layers may also be used in combination with the tape layer 120, the LWRT layer 110, and the spacer layer 910. Referring to FIG. 10, a support layer 1010 is shown. The support layer 1010 may act to hold all other layers in place. In some embodiments, the support layer 1010 comprises a plastic, a metal, a non-metal, or other material. For example, the support layer 1010 may comprise steel, aluminum, carbon, titanium, galvanized steel, or other material. The exact thickness of the support layer 1010 may vary from about 0.5 mm to about 5 cm. Similarly, the density of the support layer 1010 may be about 0.2 g / cm. 3 ~about 8.0g / cm 3 (For example, if the support layer 1010 is made of LWRT sheet, the density may vary from about 0.2 g / cm 3 ~about 0.8gm / cm 3 In certain embodiments, the support layer 1010 may be a LWRT layer similar to layer 110. For example, the support layer 1010 may comprise an open cell structure formed from reinforcing fibers held in place by a thermoplastic material. The support layer 1010 may be porous or non-porous as desired. In certain embodiments, the support layer 1010 may have any of the materials and properties described in connection with the LWRT layer 110.

[0041] In certain embodiments, a floor panel or flooring can include two or more LWRT layers in combination with a multi-ply tape layer and optionally other layers. With reference to FIG. 11, a floor panel 1100 can include a multi-ply tape layer 120 bonded to a first LWRT layer 110. The first LWRT layer 110 can be bonded to a second LWRT layer 1110. The second LWRT layer 1110 can be bonded to a spacer layer 910 bonded to a support layer 910. The second LWRT layer 1110 can be configured similarly to the first LWRT layer 110, e.g., the second layer 1110 can have any of the materials and properties described in connection with the LWRT layer 110. In some embodiments, the second LWRT layer 1110 can include reinforcing fibers held in place by a thermoplastic resin to form an open-celled web. The first LWRT layer 110 and the second LWRT layer 1110 can be the same or different. In some embodiments, the second LWRT layer 1110 comprises a substantial amount of open cell structure such that voids exist within the layer 1110. In some examples, the layer 1110 may comprise a void volume of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-80%, 20-90%, 20-10 ... , 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95%, 70-80%, 70-90%, 70-95%, 80-90%, 80-95%, or any exemplary value within these exemplary ranges.

[0042] In certain embodiments, the thermoplastic materials used to form the LWRT layer 1110 may include one or more of polyolefins (e.g., one or more of polyethylene, polypropylene, etc.), polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as blends of these materials with each other or with other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4 phenylene) compounds commercially available as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons and silicones, as well as copolymers, alloys, blends of these materials with each other, or with other polymeric materials. The thermoplastic materials used to form layer 1110 can be used in powder form, resin form, rosin form, particle form, fiber form, or other suitable form. Exemplary thermoplastic materials in various forms are described herein and also in, for example, U.S. Patent Application Publication No. 20130244528 and U.S. Patent Application Publication No. 20120065283. The exact amount of thermoplastic material present in layer 1110 can vary, with exemplary amounts ranging from about 20% by weight to about 80% by weight, such as 30-70% by weight or 35-65% by weight, based on the total weight of LWRT layer 1110. One of ordinary skill in the art will recognize that the weight percentages of all materials used in layer 1110 add up to 100% by weight.

[0043] In other embodiments, the reinforcing material of the LWRT layer 1110 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers, such as para- and meta-aramid fibers, nylon fibers, polyester fibers, high melt flow index resins suitable for use as fibers (e.g., fibers with a melt flow index (MFI) or greater than 100 g / 10 min), mineral fibers, such as basalt, mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated prior to use to provide desired functional groups or impart other physical properties to the fibers, e.g., chemically treated to allow reaction with thermoplastic materials, lofting agents, or other materials. The fiber content in the layer 1110 may independently be from about 20% to about 90% of the weight of the layer 1110, and more particularly from about 30% to about 70% of the weight of the layer 1110. The particular size and / or orientation of the fibers used may depend at least in part on the thermoplastic material used and / or the desired properties of the LWRT layer 1110. In one non-limiting example, the fibers dispersed within the thermoplastic material and optionally other additives to provide the layer 1110 may generally have a diameter greater than about 5 microns, more specifically between about 5 microns and about 22 microns, and a length between about 5 mm and about 200 mm, more specifically, the fiber diameter may be between about 2 microns and about 22 microns, and the fiber length may be between about 5 mm and about 75 mm. The fibers within the layer 1110 typically have a random orientation. The layer 1110 may also have additives as described in connection with the LWRT layer 110.

[0044] In certain embodiments, the articles described herein can be used as flooring or floor panels. With reference to FIG. 12, three panels 1210, 1220, 1230 are shown disposed adjacent to one another. Each panel 1210, 1220, 1230 can include any one or more of the various layers described herein. For example, the panel 1210 can include a tape comprising multiple fiber layers bonded together, each fiber layer of the tape comprising one directional fiber orientation, the tape comprising at least two fiber layers having different fiber orientations, and a reinforced thermoplastic layer bonded to a first surface of the tape at a first surface of the lightweight reinforced thermoplastic layer. The panel 1210 can also include a reinforced thermoplastic layer comprising an open cell web formed by a reinforcement material held in place by a thermoplastic material. The panel 1210 can also include a spacer layer bonded to a second surface of the reinforced thermoplastic layer at a first surface of the spacer layer, and a support layer bonded to the second surface of the spacer layer. Each of the panels 1210, 1220, 1230 can be the same or different. For example, referring to FIG. 12B, a panel 1240 having a 90 degree fiber orientation on its outer surface can be placed between the panels 1210, 1230. In use, the panels can be abutted against one another and a top layer or cover can be added to form the final vehicle floor. For example, a carpet, plastic or other covering layer may be placed over the panels 1210, 1220, 1230 when they are placed against one another. The exact number of panels used in any vehicle floor can vary from 2 to about 20 or more than 20. Each of the panels 1210, 1220, 1230 can independently include a tape with 2, 3, 4, 5 or 6 (or more) individual layers or plies, with at least one layer of the tape having a unidirectional fiber orientation. As described herein, an outer layer, e.g., a film, scrim, etc., can be present on one or more surfaces of the tape.

[0045] In certain configurations, the flooring and floor panels described herein may be present in vehicles, including, for example, recreational vehicles, vans, campers, buses, trucks, or other vehicles. For illustrative purposes, a recreational vehicle 1300 including a floor panel as described herein is shown in FIG. 13. The RV 1300 includes a roof 1312, side walls 1314, 1316 coupled to the roof 1312, and a floor 1318 coupled to the side walls 1314, 1316 to provide an interior space 1305 within the recreational vehicle 1300. In certain configurations, the floor includes a floor panel including a tape including multiple fiber layers bonded together, each fiber layer of the tape including a unidirectional fiber orientation, the tape including at least two fiber layers having different fiber orientations. The floor panel may also include a reinforced thermoplastic layer bonded to a first surface of the tape with a first surface of the lightweight reinforced thermoplastic layer, the reinforced thermoplastic layer including an open cell web formed by the reinforcement material held in place by the thermoplastic material. The floor panel may also include a spacer layer bonded to a second surface of the reinforced thermoplastic layer at a first surface of the spacer layer, and a support layer bonded to the second surface of the spacer layer. In some cases, the floor 1318 may include two, three, or more floor panels, as described herein. Although not shown, the floor 1318 typically includes a covering layer, e.g., fabric, tile, polymer, etc., over the floor panel. As described herein, the floor panel may include a tape having two or more plies, each of which may include a selected fiber orientation or arrangement.

[0046] The exact process used to manufacture the floors shown in Figures 12A-13 can vary. For example, each panel can be laminated independently and then assembled together to form a larger floor. Alternatively, a process can be used to manufacture a single floor laminated at one time with the seams of the individual layers overlapping. For example, the overlapping layers can be in a selected pattern, such as a tile pattern, a brick pattern, a marble pattern, etc.

[0047] In certain embodiments, the floor panel or components thereof may be packaged in the form of a kit that may include one or more components of the floor panel in combination with written or electronic instructions for bonding the reinforced thermoplastic layer to the tape layer. The kit may include a spacer layer and a support layer for providing the floor. In some embodiments, the kit may include a reinforced thermoplastic layer comprising an open-celled web formed by a reinforcement material held in place by a thermoplastic material. In other embodiments, the kit may include a tape. In a further example, the tape includes at least two fibrous layers bonded together, the first fibrous layer of the tape comprising a unidirectional fiber orientation. For example, the unidirectional fiber orientation of the first fibrous layer is orthogonal to the unidirectional fiber orientation of the second fibrous layer. In other examples, the unidirectional fiber orientation of the first fibrous layer is parallel to the unidirectional fiber orientation of the second fibrous layer. In some examples, the kit includes a spacer layer, e.g., a foam layer. For example, the kit may include a foam layer, or materials for manufacturing a foam layer, including one or more of an expanded foam material, an extruded foam, or a cast foam. Optionally, the kit can also include a support layer, such as a metal layer or a reinforced thermoplastic layer. For example, the support layer can include a second reinforced thermoplastic layer comprising an open cell web formed by the reinforcement material held in place by the thermoplastic material.

[0048] It will be recognized by those of skill in the art, given the benefit of this disclosure, that the exact form of the various layers and / or materials described herein may vary. For example, with reference to FIG. 14, layer 1410 may include one or more of a 2-ply bi-directional glass tape (e.g., from a roll of tape), a 4-ply bi-directional glass tape (e.g., in sheet form or on a roll), a 6-ply bi-directional glass tape (e.g., in sheet form), or other multi-ply tape in sheet or roll form. Each of layers 1420, 1430 may have a thickness that may vary from about 2 mm to about 6 mm and may be made from a single layer or may include multiple layers. Each of layers 1420, 1430 may be an LWRT layer as described herein and may be the same or different. Layer 1440 may be made using foamed materials, non-foamed materials, or both. In some embodiments, layer 1440 may have a thickness of 1 lb / ft 3 EPS, 1.5lb / ft 3 EPS, 2lb / ft 3 EPS, 3lb / ft 3 EPS, 4lb / ft 3 Polyurethane foam, or 6 lb / ft 3 In certain configurations, layer 1450 can be one or more of a monofilament reinforced thermoplastic layer (e.g., 2 mm to about 6 mm thick), two monofilament reinforced thermoplastic layers (e.g., 2 mm to about 6 mm total thickness), a glass layer (e.g., 2 plies of glass layer, 4 plies of glass layer), a metal layer, a flame retardant layer, or combinations thereof. Additional materials for layers 1410, 1420, 1430, 1440, and 1450 can be selected by one of skill in the art given the benefit of this disclosure.

[0049] To facilitate a better understanding of the technology described herein, specific examples are set forth.

[0050] Example 1 A floor panel was constructed that included the layers shown in FIG. 14. The panel 1400 included a 4-ply tape 1410, each layer including glass fibers oriented in one direction (fiber orientation 0 / 90 / 90 / 0). The tape included a polyethylene terephthalate scrim (not shown) on each surface. The panel included two reinforced thermoplastic layers 1420, 1430, each including polypropylene (45% by weight) and glass fibers (55% by weight). Each layer 1420, 1430 was 2.7 mm thick. A foam layer 1440 (1.5 inches thick including 3 pcf EPS foam) was adjacent to layer 1430. A galvanized steel layer 1450 was present below the foam layer 1440. This floor panel was tested in the following examples.

[0051] Example 2 Another floor panel was constructed containing the layers shown in Figure 14 except that the 4-ply tape was replaced with a 6-ply tape (fiber orientation 0 / 90 / 0 / 90 / 0 / 90). This floor panel was also tested in the following examples.

[0052] Example 3 FIG. 15 shows the results of the Janka heel indentation test for various materials including the floor panels of Example 1 and Example 2. The Janka score represents the full load on a ½ inch stylet. The minimum value of 216 converts to 864 psi. RVX / PIKO4X glass (corresponding to the 4-ply tape of Example 1) represents the floor panel of Example 1, and RVX / PIKO46X glass (6X glass represented by the 6-ply tape of Example 2) represents the floor panel of Example 2. All materials performed similarly.

[0053] Example 4 The various materials were weighed and the weights per square foot are shown in Figure 16. The floor panel of Example 1 is significantly lighter than the other materials, despite exhibiting similar performance characteristics.

[0054] Table 1 below shows the dimensions of the manufactured floor panel, measured in 8 ft x 20 ft (160 ft) 2) trailer lumber. The measured floors generally contained the layers shown in FIG. 11, except the lumber floor lacked layer 120. Layers 910 and 1010 were the same for all three floors, with layer 910 being 3 pcf EPS foam and layer 1010 being galvanized steel. An overall view of the floor is shown in FIG. 17 (abutting panels) and an alternative configuration that can be used (staggered joints) is shown in FIG. 18. The configuration of FIG. 18 includes staggered joints between different layers, such that the joints between different layers are offset or staggered. For example, individual layers or sheets of material can be stacked offset and then the entire assembly can be stacked together to form the floor.

[0055] For the wood floor, layers 110 and 1110 were 5.2 mm thick plywood. For the 6X glass floor, 6 plies of fiberglass tape were used for layer 120 and 2.7 mm thick LWRT (55% fiberglass and 45% polypropylene by weight) was used for layers 110 and 1110.

[0056] For the 4X glass floor, 4 plies of fiberglass tape were used for layer 120 and 2.7 mm thick LWRT (55% fiberglass and 45% polypropylene by weight) was used for layers 110 and 1110.

[0057] [Table 1]

[0058] The produced floor panels are significantly lighter than wood. Example 5 The ability of the floor panels to hold screws was measured. The results are shown in Figure 19. The lauan reference material (comprising two layers of 5.2 mm thick plywood) was able to hold #10 screws better than the manufactured article. For reference, 2.7 mm lauan has an average screw retention of 190 N.

[0059] Example 6 Knee load deflection was measured for the different samples (see FIG. 20). The floor panel with 6-ply glass tape deflected only 0.5 mm more than the current lauan wood floor panel over a span of 30 inches by 40 inches, even though the floor panel of Example 2 weighed significantly less. The floor panel of Example 1 provided 2.3 mm more deflection than the lauan wood floor panel. The results were consistent with the lighter 6-ply glass tape panel providing similar or better deflection performance than the heavier lauan wood floor panel.

[0060] When introducing elements of the examples disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there are one or more elements. The terms "comprising," "including," and "having" are intended to be open-ended, meaning that there may be additional elements other than the listed elements. Given the benefit of this disclosure, it will be recognized by those skilled in the art that various components of the examples can be interchanged or substituted for various components of other examples.

[0061] While certain aspects, configurations, examples, and embodiments have been described above, it will be recognized by those skilled in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and variations of the disclosed exemplary aspects, configurations, examples, and embodiments are possible.

Claims

1. a tape comprising a plurality of fibrous layers bonded together, at least two fibrous layers of the tape comprising a unidirectional fiber orientation, the tape comprising at least two fibrous layers having a different unidirectional fiber orientation; a reinforced thermoplastic layer bonded to the first surface of the tape at a first surface of the reinforced thermoplastic layer, the reinforced thermoplastic layer comprising an open cell web formed by a reinforcing material held in place by a thermoplastic material; a spacer layer bonded at a first surface of the spacer layer to a second surface of the reinforced thermoplastic layer; a support layer coupled to a second surface of the spacer layer; and A floor panel comprising:

2. 2. The floor panel of claim 1, wherein each fibrous layer of the tape includes a binder to hold the fibers in the unidirectional orientation, and the tape includes a scrim on the first surface of the tape and on the second surface of the tape.

3. 10. The floor panel of claim 1, wherein the support layer comprises one or more of galvanized steel, aluminum, a reinforced thermoplastic layer, a metal layer, a non-metallic layer, a plastic layer, or a tape layer.

4. 2. The floor panel of claim 1, wherein the support layer includes a second reinforced thermoplastic layer comprising an open cell web formed by a reinforcing material held in place by a thermoplastic material.

5. The floor panel of claim 1 further comprising a cover layer disposed on the tape layer.

6. The floor panel of claim 1 , wherein the cover layer comprises one or more of a scrim, a fabric, a plastic, a laminate, wood, or combinations thereof.

7. 2. The floor panel of claim 1, wherein the tape is a two-ply tape having two individual layers of fiber bonded together.

8. 8. The floor panel of claim 7, wherein a first fibrous layer of the tape is bonded to a second fibrous layer of the tape, and the unidirectional fiber orientation of the first fibrous layer is perpendicular to the unidirectional fiber orientation of the second fibrous layer.

9. 2. The floor panel of claim 1, wherein the tape is a four-ply tape having four individual layers of fiber bonded together.

10. 10. The floor panel of claim 9, wherein a first fibrous layer of the tape is bonded to a second fibrous layer of the tape, and the unidirectional fiber orientation of the first fibrous layer is perpendicular to the unidirectional fiber orientation of the second fibrous layer.

11. 11. The floor panel of claim 10, wherein a third fibrous layer of the tape is bonded to the second fibrous layer of the tape, and the unidirectional fiber orientation of the third fibrous layer is perpendicular to the unidirectional fiber orientation of the second fibrous layer.

12. 12. The floor panel of claim 11, wherein a fourth fibrous layer of the tape is bonded to the third fibrous layer of the tape, and the unidirectional fiber orientation of the fourth fibrous layer is perpendicular to the unidirectional fiber orientation of the third fibrous layer.

13. 12. The floor panel of claim 11, wherein a fourth fibrous layer of the tape is bonded to the third fibrous layer of the tape, and the unidirectional fiber orientation of the fourth fibrous layer is parallel to the unidirectional fiber orientation of the third fibrous layer.

14. 11. The floor panel of claim 10, wherein a third fibrous layer of the tape is bonded to the second fibrous layer of the tape, and the unidirectional fiber orientation of the third fibrous layer is parallel to the unidirectional fiber orientation of the second fibrous layer.

15. 15. The floor panel of claim 14, wherein a fourth fibrous layer of the tape is bonded to the third fibrous layer of the tape, and the unidirectional fiber orientation of the fourth fibrous layer is perpendicular to the unidirectional fiber orientation of the third fibrous layer.

16. 15. The floor panel of claim 14, wherein a fourth fibrous layer of the tape is bonded to the third fibrous layer of the tape, and the unidirectional fiber orientation of the fourth fibrous layer is parallel to the unidirectional fiber orientation of the third fibrous layer.

17. 2. The floor panel of claim 1, wherein the tape is a six-ply tape having six individual layers of fiber bonded together.

18. 17. The floor panel of claim 16, wherein a first fibrous layer of the tape is bonded to a second fibrous layer of the tape, and the unidirectional fiber orientation of the first fibrous layer is perpendicular to the unidirectional fiber orientation of the second fibrous layer.

19. 17. The floor panel of claim 16, wherein a first fibrous layer of the tape is bonded to a second fibrous layer of the tape, and the unidirectional fiber orientation of the first fibrous layer is parallel to the unidirectional fiber orientation of the second fibrous layer.

20. 2. The floor panel of claim 1, wherein the tape comprises 2 to 6 individual fiber layers each with unidirectional fiber orientation, the reinforced thermoplastic layer comprises polyolefin and inorganic reinforcing fibers, the spacer layer is a foam layer comprising expandable polystyrene foam, and the support layer comprises galvanized steel.

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