Engineered waterproof click-locking flooring and wall covering planks

Abstract

A click floor system can provide reversibility in combination with improved waterproof flooring utilizing bamboo, plastic, or other waterproof materials. The plank can include a veneer layer adhered to two surfaces of a waterproof core and a first waterproof adhesive layer that bonds the veneer layer to the surfaces of the waterproof core.

1 . An engineered waterproof plank comprising:
 (a) a veneer layer adhered to two surfaces of a waterproof core, wherein the veneer layer is selected from a group consisting of wood veneer, cork veneer, bamboo veneer, tile veneer, stone veneer, rubber veneer, decorative plastic veneer, linoleum veneer, and decorative vinyl veneer;   (b) a first waterproof adhesive layer bonding the veneer layer to the surfaces of the waterproof core;   (c) the waterproof core comprising an extruded dust and plastic composite; and   (d) at least two lateral edges each comprising a groove-protrusion combination, the groove extending laterally into the waterproof core at said lateral edges and the protrusion laterally protruding from the waterproof core at said lateral edges, wherein the groove-protrusion combination has profiles identical in shape to form a reversible click-lock edge fastening system.   
     
     
         2 . The plank of  claim 1 , further comprising at least one layer selected from a group consisting of cork, rubber, foam, and waterproof balance paper. 
     
     
         3 . The plank of  claim 2 , further comprising a second waterproof adhesive layer bonding the veneer layer to at least one of the surfaces of the waterproof core. 
     
     
         4 . The plank of  claim 1 , further comprising a cover layer over the veneer layer. 
     
     
         5 . The plank of  claim 1 , wherein said veneer layer is encapsulated in resin to render the veneer layer waterproof and wear-resistant. 
     
     
         6 . The plank of  claim 4 , said cover layer selected from a group consisting of melamine resin with aluminum oxide and polyurethane. 
     
     
         7 . The plank of  claim 1 , wherein exposure to moisture results in swelling of plank dimensions by less than 0.01%. 
     
     
         8 . The plank of  claim 1 , wherein the first waterproof adhesive layer further comprises a hot melt adhesive. 
     
     
         9 . The plank of  claim 1 , wherein the waterproof core further comprises calcium carbonate filler. 
     
     
         10 . The plank of  claim 1 , wherein the waterproof core comprises:
 (i) at least about 55% of dust selected from a group consisting of wood, bamboo, cork and a combination of two or more of wood, bamboo, and cork; and   (ii) at least about 20% of plastic selected from a group consisting of high-density polyethylene and polyvinyl chloride.   
     
     
         11 . The plank of  claim 10 , wherein the waterproof core further comprises less than 10% of additives selected from a group consisting of anti-oxidation agents, stabilizers, colorants, anti-fungus agents, coupling agents, reinforcing agents, and lubricants. 
     
     
         12 . An engineered rectangular waterproof plank comprising:
 (a) a veneer layer of decorative vinyl adhered to the two surfaces of a waterproof core by a hot melt adhesive;   (b) a cover layer over the veneer layers, said cover layer selected from a group consisting of melamine resin with aluminum oxide and polyurethane;   (c) the waterproof core comprising an extruded dust and plastic composite, said waterproof core having substantially two surfaces separated by a thickness defining a first lateral edge along the first side and a second lateral edge along an opposite second side, and third and fourth lateral edges along opposite third and fourth sides, wherein at least two opposite lateral edges each comprise a groove-protrusion combination, the groove extending laterally into the waterproof core at said at least two opposite lateral edges and the protrusion laterally protruding from the waterproof core at said at least two opposite lateral edges, wherein the groove-protrusion combination has profiles identical in shape to form a reversible click-lock edge fastening system.   
     
     
         13 . The plank of  claim 12 , wherein the static coefficient of friction of the plank is at least 0.60 as measured according to ASTM C 1028-96. 
     
     
         14 . The plank of  claim 12 , wherein exposure to moisture results in swelling of plank dimensions by less than 0.01%. 
     
     
         15 . The plank of  claim 12 , wherein the waterproof core comprises:
 (i) at least about 55% of dust selected from a group consisting of wood, bamboo, cork and a combination of two or more of wood, bamboo and cork; and   (ii) at least about 20% of plastic selected from a group of high-density polyethylene and polyvinyl chloride.   
     
     
         16 . The plank of  claim 15 , wherein the waterproof core further comprises less than 10% of additives selected from a group consisting of anti-oxidation agents, stabilizers, colorants, anti-fungus agents, coupling agents, reinforcing agents and lubricants. 
     
     
         17 . The plank of  claim 15 , wherein the waterproof core further comprises calcium carbonate filler. 
     
     
         18 . An engineered rectangular waterproof plank comprising:
 (a) a veneer layer selected from a group consisting of cork veneer, bamboo veneer, and wood veneer, said veneer layer encapsulated in resin, and said veneer layer adhered to the two surfaces of a waterproof core by a hot melt adhesive;   (b) a cover layer over the veneer layers, said cover layer selected from a group consisting of melamine resin with aluminum oxide, and polyurethane; and   c) the waterproof core comprising:   (i) at least about 55% of dust selected from a group consisting of wood, bamboo and cork and a combination of two or more of wood, bamboo, and cork;   (ii) at least about 20% of high-density polyethylene; and   (iii) calcium carbonate filler, said waterproof core having substantially two surfaces separated by a thickness defining a first lateral edge along the first side and a second lateral edge along an opposite second side, and third and fourth lateral edges along opposite third and fourth sides, wherein at least two opposite lateral edges each comprise a groove-protrusion combination, the groove extending laterally into the waterproof core at said at least two opposite lateral edges and the protrusion laterally protruding from the waterproof core at said at least two opposite lateral edges, wherein the groove-protrusion combination has profiles identical in shape to form a reversible click-lock edge fastening system.   
     
     
         19 . An engineered waterproof plank comprising:
 (a) wear layers adhered to two surfaces of a waterproof core;   (b) waterproof adhesive layers bonding the wear layers to the surfaces of the waterproof core;   (c) the waterproof core comprising an extruded dust and plastic composite;   (d) cover layers over the wear layers said cover layers being selected from a group consisting of melamine resin with aluminum oxide and polyurethane; and   (e) at least two opposite lateral edges, each comprising a groove-protrusion combination, the groove extending laterally into the waterproof core at said at least two opposite lateral edges and the protrusion laterally protruding from the waterproof core at said at least two opposite edges, wherein the groove-protrusion combination has profiles identical in shape to form a reversible click-lock edge fastening system.   
     
     
         20 . The plank of  claim 19 , wherein the wear layer is selected from a group consisting of tile veneer, stone veneer, rubber, decorative plastic, linoleum, and decorative vinyl. 
     
     
         21 . The plank of  claim 19 , further comprising at least one layer selected from a group consisting of cork, rubber, foam, and waterproof balance paper. 
     
     
         22 . An engineered waterproof plank comprising:
 (a) wear layers adhered to the two surfaces of a waterproof core;   (b) waterproof adhesive layers bonding the wear layers to the surfaces of the waterproof core;   (c) the waterproof core comprising an extruded dust and plastic composite;   (d) at least two opposite lateral edges each comprising a groove-protrusion combination, the groove extending laterally into the waterproof core at said at least two opposite lateral edges and the protrusion laterally protruding from the waterproof core at said at least two opposite lateral edges, wherein the groove-protrusion combination has profiles identical in shape to form a reversible click-lock edge fastening system; and   (e) wherein exposure to moisture results in swelling of plank dimensions by less than 0.01%.   
     
     
         23 . The plank of  claim 22 , wherein the wear layer is selected from a group consisting of tile veneer, stone veneer, rubber, decorative plastic, linoleum, and decorative vinyl. 
     
     
         24 . The plank of  claim 22 , further comprising at least one layer selected from a group consisting of cork, rubber, foam, and waterproof balance paper.