Abstract:
A Glass Plastic Composite core material for floors and walls in the form of planks, tiles, wall panels and sheets made from recycled glass or glass, polyvinyl chloride and porcelain without containing wood fibers.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present application is a continuation of U.S. application Ser. No. 14/589,878, filed Jan. 5, 2015. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates to a waterproof composite core. 
       BACKGROUND OF THE INVENTION 
       [0003]    Moisture and water particularly in flooring is the most common problem when wood based products are installed in areas such as kitchens, bathrooms, basements and commercial applications. 
         [0004]    Hardwood floors and high density wood fiber Laminate floors have been used for many years however moisture, water and other liquids destabilizes the wood fiber board allowing moisture to penetrate the core therefore not suitable for wet areas where moisture is present. Traditionally ceramic, porcelain and natural stone floors have been installed in moisture sensitive areas such as bathrooms, kitchens and basements in residential and commercial applications such as restaurants retail stores etc. 
         [0005]    To address the issues of moisture the flooring manufactures have taken several approaches to minimize the negative effect of moisture and water on wood based products such as an attempt to protect the most vulnerable part of flooring planks or tiles the edges or joints by impregnating the joints-edges of wood based tiles and planks with a resin type sealer however tests have shown that resin alone without the use of PVC to be unsuccessful in protecting the flooring or wall core edges from moisture due to core composition containing wood based products. 
         [0006]    Over the last twenty years flooring manufactures have made significant improvements such as easier installation methods and more resistant wear layers. However moisture in floors and wall panels tiles or planks continue to be a major problem for the industry. Recently new products to address the moisture of the core have been developed using as a composition based on PVC, limestone, and wood fibers from trees that are grounded into wood fibers, referred as Wood plastic composite (WPC) This composition does not resolve the moisture issues due to a high percentage of wood fibers in the WPC composition. The present Invention does not contain any wood fibers. The composition according to the invention combines recycled glass as the main mineral, sand in the form of silica in pre glass stage, PVC and plastic. Other advantages of recycled glass and sand-silica in pre glass stage do not contain moisture and do not emit volatile organic compounds (VOC) emissions. Unlike wood based that require the use of formaldehyde adhesive chemicals. Therefore the present invention adds another necessary advantage to address the industry&#39;s environmental requirements and contributes to LEED points. According to the present invention. 
       SUMMARY OF THE INVENTION 
       [0007]    The invention relates to a waterproof core plank, tile, wall panel and sheet panels or roll sheets for use in flooring and walls and to provide an environmental friendly product substituting wood based products with recycled glass and sand-silica in pre glass stage as follows. The core composition contains polyvinyl chloride, polyethylene, bonding agents, stabilizers, sand silica in the form of pre-glass stage, silica in the form of glass stage, recycled glass known as (common glass) in the form of dust, coarse particles or particles less then 3 mm in diameter. As referred wood plastic composite WPC contains a high percentage of wood fibers witch reduces the weight of the floor planks, tiles and panels, to address this and possibly reduce the weight a process called pre-expansion by submission to microwave radiation that it is performed in continuous or non-continuous mode and therefore reduce the weight of the sand-silica and recycled glass by expanding the sand-silica and recycled glass granulates or particles inferior to 3 mm in diameter. 
         [0008]    According to the invention the waterproof core with said composition provide a core that does not contain any wood fibers. Said composition, recycled glass and sand-silica in pre-glass stage do not emit VOC&#39;S and is environmentally friendly contributing highly to LEED certification points. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0009]    According to the invention  FIG. 1 , illustrates a view of a waterproof floor plank, tile, wall panel  24 , illustrating a core  18  with a thickness from 3 mm to 12 mm. Comprising a protective polyurethane based wear layer  21 . A decorative layer  16  having a thickness from 0.02 mm to 8 mm. A underlayment layer  14  with a thickness between 0.3 mm and 4 mm. Comprising a mechanical locking system  22 . And comprising a beveled edge  6  on at least 2 edges of a plank, tile or wall panel. 
           [0010]    According to the invention  FIG. 2 , illustrates a view of a waterproof floor plank, tile, wall, illustrating a core  89  with a thickness from 3 mm to 12 mm. Comprising a protective polyurethane based wear layer  121 . A decorative layer  110  having a thickness from 0.02 mm to 8 mm. A underlayment layer  19  with a thickness between 0.3 mm and 4 mm. Comprising a tongue and groove configuration  171 , 172 . And comprising a beveled edge  60  on at least 2 edges of a plank, tile or wall panel. 
           [0011]    According to the invention  FIG. 3 , illustrates a view of a flexible or ridged sheet or panel  47  with dimensions grater than 300 mm in length and 300 mm in width comprising a core  36  with a thickness between 1.6 mm to 12 mm.  FIG. 3  also illustrates a wear layer  52  consisting of a polyurethane based. A decorative layer  53  with a thickness between 0.02 mm to 4 mm. A underlayment layer  38  with a thickness from 0.3 mm to 4 mm with 90° (degree) edges. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0012]    According to  FIG. 1 , illustrates a ridged or flexible waterproof core  18  in the form of planks, tiles and wall panels  24 . For flooring and wall applications with a thickness between 3 mm and 12 mm.  FIG. 1  illustrates the core  18  with a composition consisting, of at least 42% of recycled glass or silica in pre-glass stage (sand) also sometimes called soda-lime-silica glass at least 16% of virgin or recycled polyvinyl chloride PVC, polyethylene, plastic, at least 3% of bonding agents, stabilizers and colorants.  FIG. 1  also illustrates a polyurethane based wear layer with micro ceramic or aluminum oxide scratch resistance protection  21 .  FIG. 1  also illustrates a decorative layer  16  adhered to the upper side of the core  18  consisting of PVC, wood, wood veneer, natural stone, porcelain, cork, bamboo, linoleum, bonded leather, High Definition Printing HDP, vinyl and decor paper, with a thickness from 0.02 mm to 8 mm.  FIG. 1  also illustrates a underlayment  14  adhered to the underside of the core  18  consisting of PVC, cork or rubber with a thickness between 0.3 mm and 4 mm.  FIG. 1  also illustrates a micro-beveled edge  6  on one or more edges of the plank  24 . For installation purposes the waterproof core  18  comprises of a mechanical locking system  22  that known to be licensed by VALINGE GROUP, UNILIN BEHEER BV, FLOORING INDUSTRIES LIMITED, SARL. Recognized to facilitate the installation of floating floors without the use of adhesives. Composition materials used as part of the core  18  are mixed by mechanical means and extruded into flooring planks, tiles and wall panels creating a ridged or flexible core  18 . 
         [0013]    According to  FIG. 2 , illustrates a ridged or flexible waterproof core  89  in the form of planks, tiles and wall panels  27 . For flooring and wall applications with a thickness between 3 mm and 12 mm.  FIG. 2  illustrates the core  89  with a composition consisting, of at least 42% of recycled glass or silica in pre-glass stage (sand) also sometimes called soda-lime-silica glass at least 16% of virgin or recycled polyvinyl chloride PVC, polyethylene, plastic, at least 3% of bonding agents, stabilizers and colorants.  FIG. 2  also illustrates a polyurethane based wear layer with micro ceramic or aluminum oxide scratch resistance protection  121 .  FIG. 2  also illustrates a decorative layer  110  adhered to the upper side of the core  89  consisting of PVC, wood, wood veneer, natural stone, porcelain, cork, bamboo, linoleum, bonded leather, High Definition Printing HDP, vinyl and decor paper, with a thickness from 0.02 mm to 8 mm.  FIG. 2  also illustrates a underlayment  19  adhered to the underside of the core  89  consisting of PVC, cork or rubber with a thickness between 0.3 mm and 4 mm.  FIG. 2  also illustrates a micro-beveled edge  60  on one or more edges of the plank  27 . For installation purposes the waterproof core  89  comprises a tongue and groove configuration  171 , 172 . Composition materials used as part of the core  89  are mixed by mechanical means and extruded into flooring planks, tiles and wall panels creating a ridged or flexible core  89 . 
         [0014]    According to  FIG. 3 , a flexible or ridged waterproof core  36  with a thickness between 1.6 mm and 12 mm for flooring and wall applications.  FIG. 3  illustrates the core  36  with a composition consisting, at least 42% of recycled glass or silica in pre-glass stage (sand) also sometimes called soda-lime-silica glass at least 16% of virgin or recycled polyvinyl chloride PVC, polyethylene, plastic, at least 3% of bonding agents, stabilizers and colorants.  FIG. 3  also illustrates a polyurethane based wear layer with micro ceramic or aluminum oxide scratch resistance protection  52 .  FIG. 3  also illustrates a decorative layer  53  adhered to the upper side of the core  89  consisting of PVC, cork and linoleum, vinyl with a thickness between 0.02 mm and 3 mm.  FIG. 3  also illustrates a underlayment  38  adhered to the underside of the core  36  consisting of PVC, cork or rubber with a thickness between 0.3 mm and 4 mm consisting of a core sheet with 90° (degree) edges. Composition materials used as part of the core  89  are mixed by mechanical means and extruded into sheets creating a flexible or ridged core  36 . 
         [0015]    According to  FIGS. 1 and 2  the planks, tiles and panels are generally rectangular shape width between 50 mm and 300 mm in length and for square shape length and width of 200 mm×200 mm. 
         [0016]    According to  FIG. 3  the core sheet  36  is flexible having dimensions in width and length greater than 300 mm×300 mm. 
         [0017]    A general view of the invention is the composition of the core  18  and  89  for planks, tiles and panels and  36  for sheets. Combining recycled glass, polyvinyl chloride and silica in pre-glass stage (sand). Provides the flooring industry with a truly waterproof core that is environmental friendly and do not contain wood fibers therefore protecting the environment and contributing highly to LEED certification points. Another advantage of the present invention is that recycled glass silica in pre-glass stage do not emit (VOC&#39;S) and is relatively inexpensive and abundantly available by municipalities and other organizations through their waste management recycling programs and silica in pre-glass stage is basically clean sand that is grounded to small particles. These three ingredients are then mixed by mechanical means and extruded into the desired thickness and dimensions.