Flooring products and methods of making the same

Abstract

A plank is described wherein the plank comprises a core, and optionally, a print layer, and optionally an overlay. The core includes from about 30 wt % to about 95 wt % at least one polymeric material, by weight of the core, and from about 5 wt % to about 70 wt % of least one natural fiber or flour, by weight of the core, wherein the core includes a top surface and a bottom surface, and opposing sides, wherein said plank is substantially moisture resistant, having a swelling property of from about 0.5% to about 5% by NALFA Thickness Test Section 3.2 LF 01-2003 standard, and wherein said plank includes a bow of from about 0.5% to about 4%. In addition, a method of making the plank is further described.

1 . A plank comprising: 
 a core comprising from about 30 wt % to about 95 wt % of at least one polymeric material, by weight of said core, and from about 5 wt % to about 80 wt % of at least one natural fiber or flour, by weight of said core, wherein said core has a top surface and a bottom surface, and opposing sides, wherein said plank is substantially moisture resistant, having a swelling property of from 0.5% to about 5%, by NALFA Thickness Test Section 3.2 LF 01-2003 standard, and wherein said plank includes a downward bow or dome of from about 0.5% to about 4%.    
     
     
         2 . The plank of  claim 1 , wherein said plank has a density of from about 60 lbs/ft 3  to about 85 lbs/ft 3 .  
     
     
         3 . The plank of  claim 1 , wherein said plank has a glass transition temperature of about −50° C. or higher.  
     
     
         4 . The plank of  claim 3 , wherein said glass transition temperature is from about −45° C. to about 105° C.  
     
     
         5 . The plank of  claim 1 , wherein said core has a thickness of from about 5 mm to about 20 mm, a width of from about 2 cm to about 30 cm, and a length of from about 30 cm to about 130 cm.  
     
     
         6 . The plank of  claim 1 , wherein said core has a plurality of cavities.  
     
     
         7 . The plank of  claim 1 , wherein two sides of said core are tapered or have beveled edges, wherein said sides are opposite to each other.  
     
     
         8 . The plank of  claim 1 , wherein said polymeric material comprises a melt index of from about 0.4 to about 20 grams/10 minutes.  
     
     
         9 . The plank of  claim 1 , wherein said polymeric material includes a melt index of from about 0.8 to about 3 grams/10 minutes.  
     
     
         10 . The plank of  claim 1 , wherein said polymeric material comprises a polyolefin group.  
     
     
         11 . The plank of  claim 10 , wherein said polyolefin group comprises a polyethylene.  
     
     
         12 . The plank of  claim 1 , wherein said polymeric material comprises a polypropylene, a polyvinyl chloride, a copolymer of PVC, or a combination thereof.  
     
     
         13 . The plank of  claim 1 , wherein said polymeric material comprises at least one thermoplastic material, at least one plasticizer, and at least one coupling agent.  
     
     
         14 . The plank of  claim 13 , wherein said plasticizer is present in an amount of less than about 20% by weight of said core.  
     
     
         15 . The plank of  claim 1 , wherein said natural fiber or flour includes a particle size of from about 50 mil or less.  
     
     
         16 . The plank of  claim 1 , where in said natural fiber or flour has a particle size of from about 30 mil or less.  
     
     
         17 . The plank of  claim 1 , wherein said natural fiber or flour includes from about 10 wt % to about 40 wt % of a fiber or flour having a size of from about 20 mil to about 30 mil; from about 10 wt % to about 30 wt % of a fiber or flour having a size of from about 15 mil to about 20 mil; from about 10 wt % to about 30 wt % of a fiber or flour having a size of from about 5 mil to about 15 mil, and from about 0 wt % to about 20 wt % of a fiber or flour having a size of about 5 mil or less.  
     
     
         18 . The plank of  claim 1 , wherein said natural fiber or flour comprises a moisture content of about 1 wt % or less.  
     
     
         19 . The plank of  claim 1 , wherein said natural fiber or flour comprises wood, a cellulose source other than wood, or a combination thereof.  
     
     
         20 . The plank of  claim 1 , wherein said plank has a swelling property of from 0.5% to about 3% by NALFA Thickness Test Section 3.2 LF 01-2003 standard.  
     
     
         21 . The plank of  claim 1 , wherein said plank comprises a bow of from about 0.5 inch to about 3.5 inches.  
     
     
         22 . The plank of  claim 1  further comprising at least one lubricant.  
     
     
         23 . The plank of  claim 22 , wherein said lubricant in present in an amount of from about 1% to about 5% or more, by weight of said core.  
     
     
         24 . The plank of  claim 22 , wherein said lubricant comprises a polyester lubricant.  
     
     
         25 . The plank of  claim 22 , wherein said lubricant comprises a polyolefin wax, an amide wax, a montanic acid ester, a metallic stearate, a calcium stearate, a zinc stearate, a metal salt of a long chain carboxylic acid, a paraffin, or any combination thereof.  
     
     
         26 . The plank of  claim 1  further comprising at least one compatibilizer or coupling agent.  
     
     
         27 . The plank of  claim 26 , wherein said compatibilizer or coupling agent is present in an amount of from about 0.5 wt % to about 5 wt %, by weight of said core.  
     
     
         28 . The plank of  claim 26 , wherein said compatibilizer or coupling agent comprises a maleic anhydride.  
     
     
         29 . The plank of  claim 1 , further comprising a laminate, wood veneer, vulcanized cellulose layer, or a combination thereof on said top surface.  
     
     
         30 . The plank of  claim 1 , further comprising an underlay layer located and affixed between bottom surfaces of a top layer and said top surface of said core.  
     
     
         31 . The plank of  claim 30 , wherein said underlay comprises an aminoplast resin impregnated paper.  
     
     
         32 . The plank of  claim 30 , wherein said underlay comprises Kraft paper impregnated with an aminoplast resin.  
     
     
         33 . The plank of  claim 30 , wherein an adhesive is present between said cores and said underlay layer in order to affix said underlay layer to said core.  
     
     
         34 . The plank of  claim 30 , further comprising a printed design.  
     
     
         35 . The plank of  claim 30 , further comprising a protective layer affixed to said top surface of said top layer.  
     
     
         36 . The plank of  claim 35 , wherein said protective layer comprises an aminoplast resin impregnated overlay paper and aluminum oxide imbedded on the top surface of said paper.  
     
     
         37 . The plank of  claim 35 , wherein said protective layer comprises an aminoplast resin impregnated overlay paper.  
     
     
         38 . The plank of  claim 30 , wherein said plank includes a bow of from about 2.5 inches to about 3.2 inches.  
     
     
         39 . The plank of  claim 30 , wherein said top layer comprises a decorative element.  
     
     
         40 . The plank of  claim 30 , wherein said top layer is embossed with a design.  
     
     
         41 . The plank of  claim 1 , wherein said bottom surface of said core is thermally treated.  
     
     
         42 . The plank of  claim 1 , further comprising at least one design layer.  
     
     
         43 . The plank of  claim 42 , wherein said design layer has the design of natural wood, stone, ceramic, brick, or tile.  
     
     
         44 . The plank of  claim 42 , wherein said plank further comprises a layer that has texture or said top surface of core has a textured surface or both.  
     
     
         45 . The plank of  claim 44 , wherein said design on said design layer and said texture are in register.  
     
     
         46 . The plank of  claim 44 , wherein said texture simulates the texture present in natural wood, stone, ceramic, brick, or tile.  
     
     
         47 . A floor comprising a plurality of the planks of  claim 1  joined together.  
     
     
         48 . The floor of  claim 47 , wherein the planks are joined together by a mechanical locking system.  
     
     
         49 . The floor of  claim 47 , wherein the planks are joined together by a bonding agent.  
     
     
         50 . The floor of  claim 47 , wherein the planks are joined together by a tongue and grove connection.  
     
     
         51 . The floor of  claim 47 , wherein the planks are joined together by a grove and spline system.  
     
     
         52 . The floor of  claim 47 , wherein said floor is a floating floor.