Thermoplastic planks and methods for making the same

Abstract

A thermoplastic laminate plank is described wherein the thermoplastic laminate plank includes a core, a print layer, and optionally an overlay. The core includes at least one thermoplastic material and has a top surface and bottom surface wherein a print layer is affixed to the top surface of the core and an overlay layer is affixed to the top surface of the print layer. An underlay layer can be located and affixed between the bottom surface of the print layer and the top surface of the core. In addition, a method of making the thermoplastic laminate plank is further described which involves extruding at least one thermoplastic material into the shape of the core and affixing a laminate on the core, wherein the laminate comprises an overlay affixed to the top surface of the print layer and optionally an underlay layer affixed to the bottom surface of the print layer.

1 . (canceled) 
     
     
         2 . A thermoplastic laminate plank, comprising
 a core comprising at least one thermoplastic material, wherein said core has top surface and a bottom surface, and opposing sides,   a print layer, optionally with an underlay layer, affixed to said top surface of the said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprises a printed design; and   a protective layer affixed to said top surface of said print layer,   wherein said core has a tongue design on at least one edge and a groove design on at least an opposite edge, and   wherein said core has a cellular foam structure.   
     
     
         3 . The thermoplastic laminate plank according to  claim 2 , wherein the print layer is affixed to said top surface by an adhesive. 
     
     
         4 . The thermoplastic laminate plank according to  claim 3 , wherein the adhesive is a hot melt adhesive. 
     
     
         5 . The thermoplastic laminate plank according to  claim 3 , wherein the adhesive is a hot melt glue. 
     
     
         6 . The thermoplastic laminate plank according to  claim 3 , wherein the adhesive is a hot melt polyurethane glue. 
     
     
         7 . The thermoplastic laminate plank according to  claim 2 , wherein the core further comprises wood flour. 
     
     
         8 . The thermoplastic laminate plank according to  claim 2 , wherein the core comprises a filler. 
     
     
         9 . The thermoplastic laminate plank according to  claim 8 , wherein said filler is present in an amount of from about 10 to about 35 parts by weight based on 100 parts by weight of the thermoplastic material. 
     
     
         10 . The thermoplastic laminate plank according to  claim 8 , wherein said filler is present in an amount of from about 10 to about 30 parts by weight based on 100 parts by weight of the thermoplastic material. 
     
     
         11 . The thermoplastic laminate plank according to  claim 8 , wherein said filler is present in an amount of from about 20 to about 35 parts by weight based on 100 parts by weight of the thermoplastic material. 
     
     
         12 . The thermoplastic laminate plank according to  claim 8 , wherein the filler includes calcium carbonate. 
     
     
         13 . The thermoplastic laminate plank according to  claim 2 , wherein the core comprises a blowing agent. 
     
     
         14 . The thermoplastic laminate plank according to  claim 2 , wherein the cellular foam structure is formed by mechanical injection of gas. 
     
     
         15 . The thermoplastic laminate plank according to  claim 2 , wherein the print layer is a thermoplastic film with a printed design. 
     
     
         16 . The thermoplastic laminate plank according to  claim 2 , wherein the print layer is a PVC film with a printed design. 
     
     
         17 . The thermoplastic laminate plank according to  claim 2 , wherein said at least one thermoplastic material is PVC. 
     
     
         18 . The thermoplastic laminate plank according to  claim 2 , wherein the thermoplastic material is flexible. 
     
     
         19 . The thermoplastic laminate plank according to  claim 2 , wherein the thermoplastic material is flexible PVC. 
     
     
         20 . The thermoplastic laminate plank according to  claim 2 , wherein the protective layer comprises a polyurethane coating with or without wear resistant particles in the polyurethane coating. 
     
     
         21 . The thermoplastic laminate plank according to  claim 2 , wherein the core has a thickness of from about 3 mm to about 50 mm, a width of from about 2 cm to about 60 cm, and a length of from about 30 cm to about 215 cm. 
     
     
         22 . The thermoplastic laminate plank according to  claim 2 , wherein the core has a thickness of from about 5 mm to about 20 mm, a width of from about 2 cm to about 60 cm, and a length of from about 30 cm to about 215 cm. 
     
     
         23 . The thermoplastic laminate plank according to  claim 2 , wherein the core has a thickness of from about 3 mm to about 5 mm, a width of from about 2 cm to about 60 cm, and a length of from about 30 cm to about 215 cm. 
     
     
         24 . The thermoplastic laminate plank according to  claim 2 , wherein said thermoplastic laminate plank is not susceptible to damage caused by moisture. 
     
     
         25 . The thermoplastic laminate plank according to  claim 2 , wherein the thermoplastic material has a molecular weight as reflected by inherent viscosity of from about 0.88 to about 1.0 inherent viscosity. 
     
     
         26 . The thermoplastic laminate plank according to  claim 2 , wherein the thermoplastic material is a suspension grade or mass polymerization-grade homopolymer resin. 
     
     
         27 . A thermoplastic laminate plank, comprising
 a core comprising at least one thermoplastic material and wood flour, wherein said core has top surface and a bottom surface, and opposing sides,   a print layer, optionally with an underlay layer, affixed to said top surface of the said core, wherein said print layer has a top surface and a bottom surface, wherein said print layer comprises a printed design; and   a protective layer affixed to said top surface of said print layer, and   wherein said core has a cellular foam structure.   
     
     
         28 . The thermoplastic laminate plank according to  claim 27 , wherein the adhesive is a hot melt adhesive.