US 10,889,996 B2
Engineered flooring product and method of manufacturing thereof
Derek Welbourn, Vancouver (CA); Jianming Chen, Jiangsu (CN); and Jun Zhang, Hubei (CN)
Assigned to Core Innovations Limited, Kowloon (HK)
Appl. No. 16/340,840
Filed by CORE INNOVATIONS LIMITED, Hong Kong (CN)
PCT Filed Oct. 11, 2016, PCT No. PCT/CN2016/101758
§ 371(c)(1), (2) Date Apr. 10, 2019,
PCT Pub. No. WO2018/068197, PCT Pub. Date Apr. 19, 2018.
Prior Publication US 2019/0264449 A1, Aug. 29, 2019
Int. Cl. B29C 39/00 (2006.01); E04F 15/02 (2006.01); B32B 3/06 (2006.01); B32B 5/18 (2006.01); B32B 7/12 (2006.01); B32B 9/00 (2006.01); E04F 15/10 (2006.01); B32B 13/00 (2006.01); E04F 15/08 (2006.01); C04B 22/06 (2006.01); C04B 28/32 (2006.01); B32B 13/04 (2006.01); B29C 39/10 (2006.01); B29C 39/02 (2006.01); B29C 39/12 (2006.01)
CPC E04F 15/02038 (2013.01) [B29C 39/003 (2013.01); B29C 39/025 (2013.01); B29C 39/10 (2013.01); B29C 39/123 (2013.01); B32B 3/06 (2013.01); B32B 5/18 (2013.01); B32B 7/12 (2013.01); B32B 9/005 (2013.01); B32B 13/00 (2013.01); B32B 13/04 (2013.01); C04B 22/066 (2013.01); C04B 28/32 (2013.01); E04F 15/08 (2013.01); E04F 15/107 (2013.01); B32B 2307/554 (2013.01); B32B 2307/7265 (2013.01); B32B 2419/04 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of manufacturing an engineered flooring product comprising a core layer, the core layer comprising a first hydrate compound comprising magnesium hydroxide and magnesium chloride, one or more second hydrate compounds each comprising magnesium hydroxide and magnesium sulfate, and one or more stabilizing agents, the method comprising:
(a) mixing at least magnesium oxide, magnesium chloride, magnesium sulfate, the one or more stabilizing agents, and water in a mixer, thereby forming a raw material slurry;
(b) spreading a first layer of the raw material slurry onto a cull plate;
(c) laying at least one sheet of stabilizing material on the first layer of the raw material slurry;
(d) spreading a second layer of the raw material slurry on the sheet of stabilizing material, thereby forming said core layer;
(e) curing said core layer;
(f) after said step (e), releasing said cured core layer from said cull plate;
(g) after said step (f), trimming said cured core layer released from said cull plate; and
(h) after said step (g), cooling said cured core layer released from said cull plate for at least about 24 hours at a temperature ranging from about 10° C.-30° C. to release internal stress within the cured core layer, thereby forming said engineered flooring product, said engineered flooring product having a thickness ranging from about 4 mm to about 20 mm.