US 11,794,396 B2
Method of producing a glueless dustless composite flooring material system
John B. Troendle, Harahan, LA (US)
Assigned to SUNRISE SPC TECHNOLOGY, LLC, Houston, TX (US)
Filed by SUNRISE SPC TECHNOLOGY, LLC, Houston, TX (US)
Filed on Aug. 4, 2022, as Appl. No. 17/881,091.
Application 17/881,091 is a division of application No. 17/146,087, filed on Jan. 11, 2021, granted, now 11,440,232.
Application 17/146,087 is a continuation of application No. 16/432,106, filed on Jun. 5, 2019, granted, now 10,889,040, issued on Jan. 12, 2021.
Application 16/432,106 is a continuation in part of application No. 15/194,891, filed on Jun. 28, 2016, granted, now 10,343,381, issued on Jul. 9, 2019.
Prior Publication US 2022/0371251 A1, Nov. 24, 2022
Int. Cl. B32B 27/08 (2006.01); B29C 48/00 (2019.01); E04F 15/10 (2006.01); B44C 5/04 (2006.01); B32B 27/30 (2006.01); B32B 37/06 (2006.01); B32B 37/18 (2006.01); B29K 27/06 (2006.01); B29L 31/10 (2006.01)
CPC B29C 48/022 (2019.02) [B32B 27/08 (2013.01); B32B 27/304 (2013.01); B32B 37/06 (2013.01); B32B 37/182 (2013.01); B44C 5/0453 (2013.01); E04F 15/105 (2013.01); E04F 15/107 (2013.01); B29K 2027/06 (2013.01); B29L 2031/10 (2013.01); B32B 2255/10 (2013.01); B32B 2255/20 (2013.01); B32B 2255/26 (2013.01); B32B 2307/402 (2013.01); B32B 2307/412 (2013.01); B32B 2307/554 (2013.01); B32B 2419/04 (2013.01)] 13 Claims
OG exemplary drawing
 
1. Composite flooring material segments, each composite flooring material segment comprising:
(i) a flooring base layer comprising a mixture of PVC resin and calcium carbonate,
wherein said mixture is free of glue, and
wherein said flooring base layer is a resultant of extrusion of the mixture at elevated temperature and pressure, mold-forming the extruded mixture into said flooring base layer, and cooling said flooring base layer;
(ii) a waterproof flooring face layer comprising a decorative face sublayer and a wearing face sublayer fused onto a top face of said decorative face sublayer,
where said flooring face layer is textured and fused onto a top face of said flooring base layer by hot-melt overlaying of said layers; and
(iii) a cured waterproof flooring coating layer, applied on top of said flooring face layer,
wherein said flooring coating layer is the resultant of coating said flooring face layer with a UV-curing plastic resin and UV curing said coating of UV-curing plastic resin by exposure to UV light.