Dimensionally stable product and process of fabricating a dimensionally stable product

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.

What is claimed is: 
     
         1 . 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.   
     
     
         2 . The laminate flooring product of  claim 1 , wherein the first layer further comprises a polymeric binder and plasticizer. 
     
     
         3 . The laminate flooring product of  claim 2 , wherein the plasticizer is present in a maximum amount of about 10 wt. % based on the total weight of the first layer. 
     
     
         4 . The laminate flooring product of  claim 2 , wherein the polymeric binder is present in a maximum amount of about 18 wt. % based on the total weight of the first layer. 
     
     
         5 . The laminate flooring product of  claim 1 , wherein the second layer further comprises a plastisol composition and the non-woven intermediate layer is impregnated with the plastisol composition. 
     
     
         6 . The laminate flooring product of  claim 1 , wherein the second layer further comprises a decorative sub-layer comprising ink, wherein the decorative sub-layer is positioned between the upper surface and the lower surface of the first layer. 
     
     
         7 . The laminate flooring product of  claim 1 , wherein the second layer has greater flexibility than the first layer. 
     
     
         8 . The laminate flooring product of  claim 1 , wherein the laminate flooring product further comprises a first major surface opposite a second major surface and the first major surface comprises the upper surface of the second layer and the second major surface comprises the lower surface of the bottom layer. 
     
     
         9 . The laminate flooring product of  claim 1 , wherein the bottom layer has a third thickness ranging from about 5 mils to about 30 mils as measured from the upper surface to the lower surface of the bottom layer. 
     
     
         10 . The laminate flooring product of  claim 1 , wherein the bottom layer is a film formed from at least one of vinyl polymer, polyester, polyolefin, nylon, and combinations thereof. 
     
     
         11 . The laminate flooring product of  claim 1 , wherein the non-woven intermediate layer non-woven layer includes one or both of glass and polyester. 
     
     
         12 . 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.   
     
     
         13 . The method of  claim 12 , wherein the second layer is formed by impregnated the non-woven material with the plastisol composition and gelling the plastisol composition at an elevated temperature. 
     
     
         14 . The method of  claim 13 , wherein the elevated temperature ranges from about 250° F. to about 300° F. 
     
     
         15 . The method of  claim 12 , wherein the first layer is formed by creating a mixture of the polymeric binder and plasticizer and calendering the mixture between at least two heated rolls to form the first layer. 
     
     
         16 . The method of  claim 12 , wherein the first layer of step a) has a thickness ranging from about 70 mils to about 150 mils. 
     
     
         17 . The method of  claim 12 , wherein the second layer of step a) has a thickness ranging from about 14 mils to about 60 mils. 
     
     
         18 . 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.   
     
     
         19 . The laminate flooring product of  claim 18 , wherein the first layer further comprises a first sub-layer, the first sub-layer being a wear layer, wherein the first sub-layer is positioned between the upper surface and the lower surface of the first layer. 
     
     
         20 . The laminate flooring product of  claim 18 , wherein the first layer if formed from a radiation curable composition.