On-line synchronous registering co-extrusion SPC floor and production process therefor

Patent metadata

Field	Value
Publication number	US-12466161-B2
Application number	US-202418625410-A
Country	US
Kind code	B2
Filing date	Apr 3, 2024
Priority date	Sep 25, 2019
Publication date	Nov 11, 2025
Grant date	Nov 11, 2025

Abstract

On-line synchronous registering co-extrusion SPC floor includes a base material layer, a decorative layer, and a wear-resistant layer. The decorative layer is arranged on the base material layer and provides patterns and designs. The wear-resistant layer is arranged on the decorative layer, is a transparent layer or a semi-transparent layer, and is provided with a concave-convex surface. The patterns or designs correspond to the concave-convex surface; the base material layer is composed of an elastic layer, a strength layer, and a stable layer, and shading is pressed on the bottom layer of the stable layer. Two co-extrusion lines are used for simultaneous extrusion to achieve an ABA three-layer effect of an SPC base material layer. A calender matches a synchronous registering system, and the patterns of the decorative layer are formed in a rolling manner.

First claim

The invention claimed is:

1 . A floorboard, comprising a base material layer, a decorative layer and a wear-resistant layer, wherein the base material layer has a bottom grain;
wherein the decorative layer is disposed on the base material layer, and has a pattern or design; wherein the wear-resistant layer is disposed on the decorative layer, and is a transparent or translucent layer; wherein said base material layer comprises PVC resin and stone powder, wherein a content of said stone powder in said base material layer is more than 60 wt %; wherein said transparent or translucent layer has an embossed surface; wherein the decorative layer is a PVC coloured film comprising said pattern or design on a surface thereof, wherein said surface faces said wear-resistant layer; wherein the wear-resistant layer comprises a UV coating.

2 . The floorboard of claim 1 , wherein said pattern or design corresponds to the embossed surface.

3 . The floorboard of claim 1 , wherein the base material layer consists of a three-layer structure of an elastic layer, a strength layer and a stability layer, and the bottom grain is pressed into a bottom surface of the stability layer.

4 . The floorboard of claim 3 , wherein said strength layer joins said elastic layer and/or said stability layer at an irregular melt-join line.

5 . The floorboard of claim 1 , wherein said base material layer further comprises a stabilizer and a toughener.

6 . The floorboard of claim 5 , wherein said stone powder comprises calcium powder.

7 . A method for producing a floorboard, said floorboard comprising a base material layer, a decorative layer and a wear-resistant layer, wherein the base material layer has a bottom grain; the decorative layer is disposed on the base material layer, and has a pattern or design; the wear-resistant layer is disposed on the decorative layer, and is a transparent or translucent layer;
wherein said base material layer comprises PVC resin and stone powder, wherein a content of said stone powder in said base material layer is more than 60 wt %, wherein said base material layer is extruded and subsequently said base material layer enters a region between a bottom grain roller and a conveying roller to undergo thickness-setting, and a base material layer having a bottom grain is thus obtained; wherein said transparent or translucent layer has an embossed surface; wherein the decorative layer is a PVC coloured film comprising said pattern or design on a surface thereof, wherein said surface faces said wear-resistant layer; wherein the wear-resistant layer comprises a UV coating.

8 . The method of claim 7 , wherein said decorative layer and said wear-resistant layer are pre-fitted to the base material layer by means of a glue roller and a mirror-surface roller, adjusting the conveying speeds of the bottom grain roller, the conveying roller, the mirror-surface roller, the decorative layer and the wear-resistant layer, and enter a region between an elastic roller and a pattern alignment roller;
an embossed pattern on a surface of the pattern alignment roller is applied to the wear-resistant layer in an online synchronous fashion, such that an embossed surface is produced on the wear-resistant layer, and such that the embossed surface corresponds to a pattern or design of the decorative layer.

9 . A floorboard, comprising a base material layer, a decorative layer and a wear-resistant layer, wherein the base material layer has a bottom grain;
wherein the decorative layer is disposed on the base material layer, and has a pattern or design; wherein the wear-resistant layer is disposed on the decorative layer, and is a transparent or translucent layer; wherein said base material layer comprises PVC resin and stone powder, wherein a content of said stone powder in said base material layer is more than 60 wt %; wherein said transparent or translucent layer has an embossed surface; wherein said stone powder comprises calcium powder.

10 . The floorboard of claim 9 , wherein the decorative layer is a PVC coloured film comprising said pattern or design on a surface thereof, wherein said surface faces said wear-resistant layer and wherein said transparent or translucent layer comprises a UV coating.

11 . The floorboard of claim 10 , wherein said pattern or design corresponds to the embossed surface or wherein said embossed surface deviates from said pattern or design with a deviation smaller than 3 millimeter.

12 . The floorboard of claim 11 , wherein the base material layer consists of a three-layer structure of an elastic layer, a strength layer and a stability layer, and the bottom grain is pressed into a bottom surface of the stability layer.

13 . The floorboard of claim 12 , wherein said strength layer joins said elastic layer and/or said stability layer at an irregular melt-join line.

14 . A floorboard, comprising a base material layer, a decorative layer and a wear-resistant layer, wherein the base material layer has a bottom grain;
wherein the decorative layer is disposed on the base material layer, and has a pattern or design; wherein the wear-resistant layer is disposed on the decorative layer, and is a transparent or translucent layer, wherein said transparent or translucent layer has an embossed surface; wherein any deviation between said embossed surface and said pattern is smaller than 3 millimeter; wherein said base material layer comprises PVC resin and stone powder, wherein a content of said stone powder in said base material layer is more than 60 wt; wherein said stone powder comprises calcium powder.

15 . The floorboard of claim 14 , wherein the decorative layer is a PVC coloured film comprising said pattern or design on a surface thereof, wherein said surface faces said wear-resistant layer and wherein said transparent or translucent layer comprises a UV coating.

Assignees

• Unilin Bv

Inventors

• Song Jiangang
• Fu Jiajin
• Liu Fuqing

Classifications

• E04F15/107 Primary

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title

• E04F15/105

  of organic plastics with or without reinforcements or filling materials · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B2307/554

  Wear resistance · CPC title

• B32B2307/414

  Translucent · CPC title