Abstract

The present disclosure relates to a method of manufacturing an engineered flooring product comprising a core layer. The method provides the steps of: (a) mixing a hydrate compound, one or more stabilizing agents, and water in a mixer, forming a raw material slurry; (b) spreading a first layer of the raw material slurry onto a cull plate; (c) curing the first layer of raw material slurry; (d) after step (c), releasing the cured first layer of raw material slurry from the cull plate; (e) after step (d), trimming the cured first layer of raw material slurry released from the cull plate; and, (f) after step (e), cooling the cured first layer of raw material slurry released from the cull plate for at least about 24 hours at a temperature ranging from about 10° C.-30° C. thereby forming the engineered flooring product.

IPC Classes  ?

• E04F 15/02 - Flooring or floor layers composed of a number of similar elements
• B32B 3/06 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers togetherLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for attaching the product to another member, e.g. to a support
• B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
• B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
• E04F 15/10 - Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite, hardboard
• B32B 13/00 - Layered products essentially comprising a water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• E04F 15/08 - Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. concreteFlooring or floor layers composed of a number of similar elements of glass
• C04B 22/06 - OxidesHydroxides
• C04B 28/32 - Magnesium oxychloride cements, e.g. Sorel cement
• B32B 13/04 - Layered products essentially comprising a water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such substances as the main or only constituent of a layer, next to another layer of a specific substance
• B29C 39/10 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
• B29C 39/02 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor for making articles of definite length, i.e. discrete articles
• B29C 39/00 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor
• B29C 39/12 - Making multilayered or multicoloured articles

Abstract

An engineered flooring product suitable for indoor or outdoor flooring applications, and a method of manufacturing thereof are provided. The engineered flooring product comprises a core layer, the core layer comprising: (i) a hydrate compound comprising magnesium hydroxide and magnesium chloride; (ii) one or more hydrate compounds each comprising magnesium hydroxide and magnesium sulfate; and (iii) one or more stabilizing agents. The hydrate compounds are derived at least in part from magnesium oxide. The core layer has a composition that is free of PVC and other plastic-based materials and is selected to provide one or more desired physical properties such as, but not limited to, a desired degree of water resistance, durability, and thermal expansion and contraction. The core layer preferably has a composition that provides a thermal expansion coefficient equivalent to or comparable to concrete.

IPC Classes  ?

• B29C 39/00 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor
• E04F 15/02 - Flooring or floor layers composed of a number of similar elements
• B32B 3/06 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers togetherLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for attaching the product to another member, e.g. to a support
• B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
• B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
• E04F 15/10 - Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite, hardboard
• B32B 13/00 - Layered products essentially comprising a water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• E04F 15/08 - Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. concreteFlooring or floor layers composed of a number of similar elements of glass
• C04B 22/06 - OxidesHydroxides
• C04B 28/32 - Magnesium oxychloride cements, e.g. Sorel cement
• B32B 13/04 - Layered products essentially comprising a water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such substances as the main or only constituent of a layer, next to another layer of a specific substance
• B29C 39/10 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
• B29C 39/02 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressureApparatus therefor for making articles of definite length, i.e. discrete articles
• B29C 39/12 - Making multilayered or multicoloured articles