US 12,404,682 B2
Rigid polymeric modular flooring plank with CPVC and method of making same
Zachary Hoffman, Kennesaw, GA (US); and Brian Kuritz, Dallas, GA (US)
Assigned to MANNINGTON MILLS, INC., Salem, NJ (US)
Filed by Mannington Mills, Inc., Salem, NJ (US)
Filed on Jan. 12, 2023, as Appl. No. 18/096,031.
Claims priority of provisional application 63/302,141, filed on Jan. 24, 2022.
Prior Publication US 2023/0235574 A1, Jul. 27, 2023
Int. Cl. E04F 15/10 (2006.01); B32B 5/18 (2006.01); B32B 27/06 (2006.01); B32B 27/08 (2006.01); B32B 27/20 (2006.01); B32B 27/22 (2006.01); B32B 27/30 (2006.01); C08L 27/06 (2006.01); E04F 15/18 (2006.01)
CPC E04F 15/105 (2013.01) [B32B 5/18 (2013.01); B32B 27/065 (2013.01); B32B 27/08 (2013.01); B32B 27/20 (2013.01); B32B 27/22 (2013.01); B32B 27/304 (2013.01); C08L 27/06 (2013.01); E04F 15/107 (2013.01); E04F 15/181 (2013.01); B32B 2255/10 (2013.01); B32B 2255/26 (2013.01); B32B 2272/00 (2013.01); B32B 2307/554 (2013.01); B32B 2419/00 (2013.01); C08L 2205/025 (2013.01); C08L 2205/035 (2013.01); C08L 2205/06 (2013.01); C08L 2207/20 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A rigid polymeric modular flooring plank comprising
a) a core layer having a top surface and a bottom surface,
b) an optional intermediate layer having a top surface and bottom surface and laminated to said top surface of said core layer,
c) a decorative layer having a top surface and a bottom surface and laminated to said top surface of said intermediate layer if present or to said top surface of said core layer, and
d) a wear layer laminated to said top surface of said decorative layer,
wherein said core layer comprises at least one plasticized rework/scrap material comprising recycled or reclaimed plasticizer and at least one polyvinyl chloride (PVC) that comprises a chlorinated polyvinyl chloride (CPVC), the plasticized rework/scrap material (RW) and the CPVC are present in an amount so as to have a CPVC/RW weight ratio of at least 0.2, the CPVC is in an amount of from 25 wt % to 40 wt % based on total weight of the core layer, said at least one PVC further comprises at least one PVC that is not chlorinated and present in an amount of from 0.1 wt % to 20 wt % based on total weight of the core layer, and said rigid polymeric modular flooring plank or said core layer is ASTM F3261 compliant.