Abstract:
Described herein is a dimensionally stable flooring product comprising a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils, a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and a bottom layer having an upper surface opposite a lower surface, wherein the upper surface of the second layer is heat-adhered to the lower surface of the first layer and the upper surface of the bottom layer is coupled to the lower surface of the first layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/225,777 filed on Sep. 6, 2011. The disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD OF THE INVETNION 
       [0002]    The present invention relates to dual layer products, and processes for fabricating dual layer products. More specifically, the present invention relates to heat-adhered dimensionally stable products and processes of fabricating such products. 
       BACKGROUND 
       [0003]    Laminated products, such as vinyl flooring laminate, are used in various facilities and applications where dimensional stability or buckling resistance are desired. Laminated products are also used in ceilings, walls, table-tops, counter-tops, cabinets, or other suitable applications. 
         [0004]    Some vinyl laminated products suffer from a drawback of being rough, having inconsistent surfaces, and/or being further misaligned over time. For example, some laminated. products are further misaligned though dimensional instability between layers of the laminated products. In these products, when one or more than one layer is subjected to extreme temperatures, the expansion and/or contraction of such layers results in relative movement of the layers or portions of the layers. Such relative movement can result in delamination, separation of the layers, bubbles, buckling, cracking, curling, other undesirable consequences, or combinations thereof. In one known product, such dimensional instability results in end gap openings of flooring of up to between about 48 mils and about 96 mils on a four foot plank. 
         [0005]    Glass sheet products have better dimensional stability than known vinyl laminated products. However, glass sheet products are too flexible for certain applications, may undesirably buckle, may be undesirably semi-translucent or semi-transparent (for example, when married to a rigid dark colored backing), may not bridge subfloor irregularities, and/or may lack desired adhesion between separate layers. 
         [0006]    Such drawbacks of vinyl laminated products and glass sheet products can be intensified when flexible layers are adhered to rigid products. 
         [0007]    A dimensionally stable product having a flexible layer adhered to a rigid layer, and a process of fabricating such a product that do not suffer from e of the above drawbacks would be desirable in the art. 
       BRIEF SUMMARY 
       [0008]    The present invention is directed to a laminate flooring product comprising: a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils as measured from the upper surface to the lower surface of the first layer; and a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils as measured from the upper surface and the lower surface of the second layer, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and a bottom layer having an upper surface opposite a lower surface; wherein the upper surface of the second layer is heat-adhered to the lower surface of the first layer and the upper surface of the bottom layer is coupled to the lower surface of the first layer. 
         [0009]    Other embodiments of the present invention include a method of forming a laminate flooring product comprising: a) providing a first layer and a second layer, the second layer comprising a non-woven material and a plastisol composition and the first layer comprising polymeric binder and plasticizer; b) positioning the first layer adjacent to the second layer; and c) heat-adhering the first layer to the second layer to form the laminate flooring product. 
         [0010]    Other embodiments of the present invention include a laminate flooring product comprising a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils as measured from the upper surface to the lower surface of the first layer; and a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils as measured from the upper surface and the lower surface of the second layer, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and wherein the upper surface of the second layer is coupled to the lower surface of the first layer; and wherein the second layer has greater flexibility than the first layer. 
         [0011]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0013]      FIG. 1  illustrates an exemplary product laving a flexible layer and a rigid layer according to an embodiment of the disclosure. 
           [0014]      FIG. 2  illustrates an exemplary product having a flexible layer and a rigid layer according to an embodiment of the disclosure. 
           [0015]      FIG. 3  is a flow chart of an exemplary process of forming flexible according to an embodiment of the disclosure. 
           [0016]      FIG. 4  is a flow chart of another exemplary process of forming a rigid layer for a product according to an embodiment of the disclosure. 
           [0017]    Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0019]    As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls. 
         [0020]    Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material. 
         [0021]    Provided is a product, a melt-processed layer, a flexible layer, and a process of fabricating a product. Embodiments of the present disclosure provide dimensional stability, provide resistance to buckling, provide resistance to show-through (for example, of rigid dark colored backing), provide resistance to subfloor irregularities, provide wear resistance, reduce costs (for example, by decreasing the amount of delaminated product), provide visual quality, provide desirable installation characteristics (such as, smooth surfaces), are capable of being used in various types of products (for example, vinyl flooring laminates, installed floating floors, and/or full spread floors), and combinations thereof. 
         [0022]    Referring to  FIG. 1 , in one embodiment, a product  100  includes a first layer  102  and a second layer  104  heat-adhered to the first layer  102 . The heat adherence secures the first layer  102  and the second layer  104  through any suitable mechanism, such as, thermoplastic bonding, diffusion between layers catalyzed by applying heat, reaction of a heat-sensitive material between or at the abutting portion of the layers, any other suitable heat-activated adherence, or combinations thereof. In some embodiments of the disclosure, the first layer  102  and/or the second layer  104  are capable of being used in products (not shown) that are not heat-adhered. Similarly, while some embodiments of the process disclosed herein include the first layer  102  and the second layer  104  being heat-adhered, other embodiments include the first layer  102  and the second layer  104  being fabricated for such other products and/or being secured by additional or alternative mechanisms. 
         [0023]    The product  100  includes an suitable features. For example, in one embodiment, the product  100  includes beveled or unbeveled edges that are painted or stained to provide decorative advantages. In one embodiment, the product  100  is offset-laminated to provide a shiplap joint for use in floating floor installations. In one embodiment, the product  100  includes features to provide grip or support for use in floating floor installations. In one embodiment, the product  100  is cut into planks longer than four feet, limited only by print repeat in some cases. In one embodiment, the product  100  is mechanically embossed, including embossed-in-register, prior to cutting. 
         [0024]    The second layer  104  has greater flexibility than the first layer  102 . Despite the first layer  102  and the second layer  104  having differing degrees of flexibility, the product  100  has dimensional stability. As used herein, the term “dimensional stability” refers to being substantially resistant to separation of layers, either in whole or in part, usually attributable to relative movement of such layers when one or more of the layers are subjected to a temperature above or below the temperature of one or more other layers. For example, in one embodiment, dimensional stability results in the product  100  being substantially resistant to delamination, retaining a substantially planar profile, having resistance to shrinkage in use over time, or combinations thereof. In one embodiment, the product has a predetermined dimensional stability shrinkage (amount of change of length of test piece when temperature tested), for example, between about 0.2% and about 0.3%, between about 0.1% and about 0.3%, between about 0.05% and about 0.3%, between about 0.1% and about 0.2%, between about 0,05% and about 0.1%, between about 0.04% and about 0.06%, less than about 0.3%, less than about 0.2%, less than about 0.1%, less than about 0.06%, less than about 0.05%, or any suitable combination or sub-combination thereof. 
         [0025]    In one embodiment, the first layer  102  includes a vinyl composition. Suitable vinyl compositions include, but are not limited to, polyvinylchloride (including copolymers and/or homopolymers), luxury vinyl tile, vinyl compositions of vinyl composition tile, and vinyl compositions of vinyl asbestos tile (or products replacing asbestos). In a further embodiment, the vinyl composition includes one or more plasticizers, one or more stabilizers, one or more binders, one or more fillers, and/or one or more pigments, such as a chloride processing pigment (for example, titanium dioxide). In one embodiment, the first layer  102  includes biobased materials (for example, materials having a carbon signature identifying the materials as being from a non-synthetic source), recycled materials (for example, materials capable of being identified as being from a previously used product), renewable materials (for example, materials capable of being decomposed), or combinations thereof. To increase the flatness and rigidity of the first layer  102 , in one embodiment, the vinyl composition includes a predetermined concentration of the plasticizer (for example, a relatively high concentration) and a predetermined concentration of the binder (for example, a relatively low concentration). 
         [0026]    The predetermined concentration of the plasticizer in the vinyl composition is, by weight, between about 4% and about 10%, between about 5% and about 7%, between about 5% and about 6%, between about 6% and about 10%, between about 6% and about 7%, between about 8% and about 10%, between about 8% and about 9%, about 9%, about 8%, about 7%, about 6%, about 5%, greater than about 4%, greater than about 5%, greater than about 6%, or any suitable combination or sub-combination thereof. In one embodiment, the plasticizer includes or is a non-phthalate plasticizer. 
         [0027]    The predetermined concentration of the binder in the vinyl composition is, by weight, between about 15% and about 1.8%, between about 1.5% and about 17.5%, between about 1.5% and about 17%, between about 15% and about 16%, between about 12% and about 17%, between about 13% and about 17%, at about 17.5%, at about 17%, at about 16%, at about 15%, or any suitable combination or sub-combination thereof. In one embodiment, the binder includes or is any suitable polymeric material. 
         [0028]    The first layer  102  is formed by any suitable process. In one embodiment, a portion or all of the vinyl composition of the first layer  102  (for example, the resin(s), the plasticizer(s), and the filler(s)) is blended and mixed, then milled and melt-processed to form the first layer  102 . The melt-processing is by calendering, extruding, continuous mixing, molding, milling, other melt-processes, or a combination thereof. In one embodiment, the first layer  102  is additionally passed through two or more rolls to achieve desired properties, such as, thickness. 
         [0029]    In one embodiment, the first layer  102  is formed by calendering. In this embodiment, the first layer  102  is formed by forming a precursor (not shown) having a predetermined thickness (for example, between about 85 mils and about 95 mils, between about 85 mils and about 90 mils, between about 90 mils and about 95 mils, or any suitable combination or sub-combination thereof). The precursor is heated to a predetermined temperature (for example, between about 300° F. and about 400° F., between about 330° F. and about 390° F., between about 370° F. and about 390° F., between about 330° F. and about 350° F., or any suitable combination or sub-combination thereof). In one embodiment, the precursor is built up by applying more of the precursor and subsequent heating, for example, to the same temperatures or slightly higher temperatures. The precursor is then processed, for example, by pressure from a calender, to form the first layer  102 . In one embodiment, the first layer  102  includes a predetermined thickness, for example, between about 40 mils and 250 mils, between about 70 mils and 250 mils, about 170 mils and 250 mils, about 70 mils and 150 mils, between about 70 mils and 160 mils, between about 40 mils and 160 mils, at least 70 mils, at least 90 mils, at least 120 mils, at least 150 mils, or any suitable combination or sub-combination thereof. 
         [0030]    Referring again to  FIG. 1 , in one embodiment, the first layer  102  is secured to a bottom layer  106 , for example, through lamination and/or by an adhesive. The adhesive is any suitable adhesive, for example, such as a hot melt adhesive, a pressure sensitive acrylic adhesive, or a structural and/or reactive adhesive. In one embodiment, the bottom layer  106  is a rigid black polyvinyl chloride film, but may be formed, for example, from a film or tape comprising plastic, vinyl, polyester, polyolefin, nylon, or combinations thereof. In further embodiments, the bottom layer  106  includes recycled material, such as post industrial or post consumer scrap, is rigid or flexible, is moisture resistant or waterproof, or has any other suitable properties. In one embodiment, the bottom layer  106  has a predetermined thickness, for example, between about 5 mils and about 30 mils, between about 15 mils and about 30 mils, between about 25 mils and about 30 mils, at least 5 mils, at least about 10 mils, at least about 15 mils, at least about 25 mils, or any suitable combination or sub-combination thereof. 
         [0031]    In one embodiment, the bottom layer  106  includes multiple layers, such as two layers of film laminated with a mat, such as a glass mat or polyethylene terephthalate mat. Additionally or alternatively, in one embodiment, the bottom layer  106  includes a continuous or discontinuous ink, antimicrobial properties, sound-dampening properties, cushioning properties, slide resistant properties, stiffening properties, channeling properties, mechanically embossed texture, chemical texture, or combinations thereof. Similarly, in one embodiment, the first layer  102  includes such features and/or printed or textured portions on either surface of the first layer  102 . 
         [0032]    The second layer  104  has a predetermined thickness and is secured to the first layer  102 . For example, in one embodiment, the predetermined thickness is between about 14 mils and about 60 mils, between about 20 mils and about 40 mils, less than about 60 mils, less than about 50 mils, less than about 40 mils, less than about 30 mils, less than about 25 mils, less than about 20 mils, or any suitable combination or sub-combination thereof. In one embodiment, the second layer  104  includes a non-woven layer  108 , a decorative layer  110 , and a wear layer  112 . 
         [0033]    The non-woven layer  108  includes a non-woven material, such as a scrim, as a base to build up the layer. In one embodiment, the non-woven layer  108  has thickness between about 10 mils and about 30 mils, between about 10 mils and about 20 mils, between about 20 mils and about 30 mils, between about 10 mils and about 15 mils, between about 15 mils and about 20 mils, or any suitable combination or sub-combination thereof. In one embodiment, the non-woven layer  108  is resistant to softening up to a predetermined temperature (for example, 420° F.). The non-woven material includes one or both of glass and polyester, which is then saturated with plastisol (a suspension of polyvinyl chloride particles in a plasticizer), for example, by being processed on large heated rolls with the plastisol coating and filling voids in a grid of the non-woven material. The plastisol further secures the second layer  104  to the first layer  102 . In one embodiment, the non-woven layer  108  includes an intermediate layer (not shown) on one or both of the top and the bottom surface. The intermediate layer includes a gel coating, a tacky outer surface of the plastisol coating that is partially-cured or partially-solidified, a foam coating, or any suitable combination thereof. 
         [0034]    In one embodiment, the decorative layer  110  includes a printable plastisol layer  114 . In one embodiment, the printable plastisol layer  114  has a predetermined thickness, for example, between about 4 mils and 40 mils, between about 10 mils and about 20 mils, between about 20 mils and about 30 mils, between about 7 mils and about 11 mils, or any suitable combination or sub-combination thereof. In one embodiment, the printable plastisol layer  114  is applied as a coating to the non-woven layer  108 , then a pigment or ink coating layer  116  is applied onto the printable plastisol layer  114  and/or is rendered a solid or gelled by intermediate heat treatment (for example, between about 250° F. and about 300° F.). In further embodiments, the printable plastisol layer  114  includes a white base or other pigmentation. Alternatively, the printable plastisol layer  114  includes the intermediate layer. In one embodiment, the ink coating layer  116  includes pigments or other printing on film or other suitable material applied to the printable plastisol layer  114  by, for example, rotogravure printing. In one embodiment, the ink coating layer  116  has a predetermined thickness, for example, between about 0.1 mils and about 0.5 mils, between about 0.3 mils and about 0.5 mils, between about 0.1 mils and 0.3 mils, less than 0.5 mils, or any suitable combination or sub-combination thereof. 
         [0035]    In one embodiment, the wear layer  112  includes a plastisol clearcoat layer  118  and a coating wear layer  120 . In one embodiment, the plastisol clearcoat layer  118  has a predetermined thickness, for example, between about 0.1 mils and about 40 mils, between about 10 mils and about 40 mils, between about 10 mils and about 20 mils, between about 20 mils and about 30 mils, less than about 40 mils, less than about 20 mils, or any suitable combination or sub-combination thereof. In one embodiment, the coating wear layer  120  has a predetermined thickness, for example, between about 0.1 mils and about 5 mils, between about 1 mil and about 5 mils, between about 3 mils and about 5 mils, between about 0.1 mils and about 0.5 mils, less than about 5 mils, less than about 1 mil, less than about 0.5 mils, about 0.5 mils, or any suitable combination or sub-combination thereof. The plastisol clearcoat layer  118  is applied to the ink layer  116 . After the plastisol clearcoat layer  118  is allowed to cool and expand, the coating wear layer  120  is applied onto it. The coating wear layer  120  is a polymeric film, such as a radiation-curable coating, a thermally-curable coating, or other suitable material. The coating is radiation-cured, for example, by use of electron beam or ultra-violet light, or combination thereof. In one embodiment, after the coating wear layer  120  is applied and cured, the product  100  is further cooled, and then press diecut into planks, tiles, or any other suitable product. 
         [0036]    Referring to  FIG. 2 , in one embodiment, a product  200  similar to the product  100  of  FIG. 1  includes the first layer  102  and a second layer  204  heat-adhered to the first layer  102 . In one embodiment, the second layer  204  includes the non-woven layer  108 , the decorative layer  110 , a protective layer  206 , and a wear layer  208 . The protective layer  206  includes a plastisol clearcoat layer  210  applied to the ink coating layer  116 , with a coating wear layer  212  applied on the plastisol clearcoat layer  210  (the coating wear layer  212  having been applied after the plastisol clearcoat layer  210  was allowed to cool and expand). In one embodiment, the plastisol clearcoat layer  210  includes the intermediate layer (not shown) on one or both of the top and the bottom surface. In one embodiment, decorative layer  110  is devoid of the pigment or ink coating layer  116 , and additionally or alternatively, a clear film  214  includes printing. 
         [0037]    In one embodiment, the coating wear layer  212  is a radiation-curable coating. The coating wear layer  212  includes the clear film  214  and a surface coating  216 . The surface coating  216  is a radiation-curable coating or other suitable material. In one embodiment, after the surface coating  216  is applied and cured, the product  200  is further cooled, and then press diecut into planks or tiles or any other suitable product. 
         [0038]    Referring to  FIG. 3 , in one embodiment, a process  300  of fabricating a product (for example, the product  100  of  FIG. 1  or the product  200  of  FIG. 2 ) or a portion of the product (for example, the second layer  104 ) includes preparing the non-woven material (step  302 ), for example, by unwinding a flexible roll of the non-woven material. The process  300  then includes saturating the non-woven material to form the non-woven layer step  304 ), for example, by rendering it a solid or gelling with plastisol. Next, the process  300  includes forming the intermediate layer on or in the non-woven layer (step  306 ) and applying and curing one or more of the coatings and/or layers described above (step  308 ), thereby forming the second layer (step  310 ). In a further embodiment, the process  300  includes positioning the second layer on the first layer (step  312 ) and heat adhering the second layer to the first layer (step  314 ) to form the product. As will be appreciated, the process  300  includes any other suitable steps for forming the features described above. 
         [0039]    Referring to  FIG. 4 , in one embodiment, a process  400  of fabricating a product (for example, the product  100  of  FIG. 1  or the product  200  of  FIG. 2 ) or a portion of the product (for example, the first layer  104 ) includes blending, milling, and/or melt-processing a composition (for example, the vinyl composition) to form the first layer (step  402 ). The process  400  continues by heating the first layer (step  404 ). In a further embodiment, the process  400  further includes positioning the first layer to receive the second layer (step  404 ) and heat adhering the second layer to the first layer (step  406 ). As will be appreciated, the process  400  includes any other suitable steps for forming the features described above. In one embodiment, the process  400  described with reference to  FIG. 4  and the process  300  described with reference to  FIG. 3  are combined to form the product  100  having the first layer  102  and the second layer  104 . 
         [0040]    While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.