U.S. patent application number 11/175642 was filed with the patent office on 2007-01-11 for three layer composite panel from recycled polyurethanes.
Invention is credited to Reinhard Kessing, John M. Moore.
Application Number | 20070009743 11/175642 |
Document ID | / |
Family ID | 37618638 |
Filed Date | 2007-01-11 |
United States Patent
Application |
20070009743 |
Kind Code |
A1 |
Kessing; Reinhard ; et
al. |
January 11, 2007 |
Three layer composite panel from recycled polyurethanes
Abstract
A process for the manufacture of a three layer composite panel
with improved moisture resistance, minimal thickness swell, thermal
stability, and a smooth hard surface suitable for direct
lamination. The composite panel is produced utilizing recycled
polyurethanes, preferably obtained from vehicle headliners,
insulated foam panels, foam insulation, energy absorbent panels,
and polyisocyanurate foams along with materials incidental to at
least one recycled component including composite resins, cloth,
adhesives, fiberglass, and plastics. The composite panel is
composed of a core layer pressed between two surface layers.
Inventors: |
Kessing; Reinhard; (Miami,
FL) ; Moore; John M.; (Miami, FL) |
Correspondence
Address: |
LOTT & FRIEDLAND, P.A.
P.O. BOX 141098
CORAL GABLES
FL
33114-1098
US
|
Family ID: |
37618638 |
Appl. No.: |
11/175642 |
Filed: |
July 6, 2005 |
Current U.S.
Class: |
428/423.1 |
Current CPC
Class: |
B32B 5/18 20130101; B32B
2309/04 20130101; B29K 2105/04 20130101; B29B 17/0042 20130101;
Y10T 428/31554 20150401; B32B 2309/12 20130101; Y02W 30/62
20150501; B32B 5/32 20130101; B32B 2307/56 20130101; Y10T 428/31551
20150401; Y10T 428/249953 20150401; B32B 2272/00 20130101; B29K
2995/0001 20130101; B32B 27/40 20130101; B29L 2007/002 20130101;
B32B 2607/00 20130101; B32B 2266/0278 20130101; B32B 2309/02
20130101; B32B 2375/00 20130101; B32B 2305/70 20130101; B29K
2075/00 20130101; B32B 2305/70 20130101; B32B 2375/00 20130101 |
Class at
Publication: |
428/423.1 |
International
Class: |
B32B 27/40 20060101
B32B027/40 |
Claims
1. A composite panel comprising: a core composed of recycled
polyurethanes along with other materials incidental to at least one
recycled component; and two surface layers on either side of said
core composed of said recycled polyurethanes along with said other
materials incidental to said at least one recycled component,
wherein said core and said surface layers are each blended with a
binding agent and water and compressed together to form a three
layer composite panel.
2. The composite panel of claim 1, wherein said recycled
polyurethanes are recycled polyisocyanurate foams.
3. The composite panel of claim 1, wherein said recycled
polyurethanes are recycled insulated foam panels.
4. The composite panel of claim 1, wherein said recycled
polyurethanes are recycled energy absorbent panels.
5. The composite panel of claim 1, wherein said recycled
polyurethanes and said materials incidental to said at least one
recycled component are from a vehicle.
6. The composite panel of claim 1, wherein said recycled
polyurethanes and said materials incidental to said at least one
recycled component are from vehicle headliners.
7. The composite panel of claim 1, wherein said recycled
polyurethanes are selected from the group consisting of recycled
polyisocyanurate foams, recycled insulated foam panels, recycled
energy absorbent panels, recycled vehicle headliners, and mixtures
thereof.
8. The composite panel of claim 1, wherein said materials
incidental to said at least one recycled component are selected
from the group consisting of composite resins, cloth, adhesives,
fiberglass, plastics, and mixtures thereof.
9. The composite panel of claim 1, wherein said surface layers are
composed of particles about 1.5 millimeters or less in
diameter.
10. The composite panel of claim 1, wherein said core is composed
of particles about 3 millimeters or less in diameter.
11. The composite panel of claim 1, wherein said binding agent is
isocyanate.
12. The composite panel of claim 1, wherein said binding agent is
diphenylmethane diisocyanate.
13. The composite panel of claim 1, wherein said core and said
surface layers are compressed together either by a pre-press and a
main press utilizing temperatures ranging from 40.degree. C. to
185.degree. C., at a speed of 10 to 16 seconds per millimeter
thickness of the panel, and at a pressure range of about 5 kg per
sq. cm. to about 45 kg per sq. cm, or a continuous belt press
system with similar temperatures, pressures, and speeds.
14. A process of forming a composite panel from recycled
polyurethanes along with other materials incidental to at least one
recycled component comprising the steps of: a. forming a core layer
comprising the steps of: cutting and milling said recycled
polyurethanes along with said other materials incidental to said at
least one recycled component; passing the milled polyurethanes and
said other materials incidental to said at least one recycled
component through a screen to ensure all particles are not larger
than about 3 millimeters in diameter; blending said recycled
polyurethane and said other materials incidental to said at least
one recycled component with isocyanate and water, wherein a volume
of said isocyanate is approximately 3% to 10% by weight and a
volume of said water is approximately 1% to 9% by weight; cleaning
said recycled polyurethane and said other materials incidental to
said at least one recycled component in a wind sifter; b. forming
surface layers comprising the steps of: cutting and milling said
recycled polyurethane along with said other materials incidental to
said at least one recycled component; blending said recycled
polyurethane and said other materials incidental to said at least
one recycled component with isocyanate and water; cleaning said
recycled polyurethane and said other materials incidental to said
at least one recycled component in a wind sifter; passing said
milled polyurethane and said other materials incidental to said at
least one recycled component through a screen to ensure all
particles are not larger than about 1.5 millimeters in diameter; c.
forming a three layer mat with said blended core layer and said
blended surface layers wherein said core layer is between said
surface layers; and d. pressing said mat with a press system at
temperatures from about 40.degree. C. to about 185.degree. C. at a
speed of about 10-16 seconds per millimeter of panel thickness with
a pressure of about 5 kg/cm.sup.2 to about 45 kg/cm.sup.2.
15. The process of claim 14, wherein said recycled polyurethanes
are recycled polyisocyanurate foams.
16. The process of claim 14, wherein said recycled polyurethanes
are recycled insulated foam panels.
17. The process of claim 14, wherein said recycled polyurethanes
are recycled energy absorbent panels.
18. The process of claim 14, wherein said recycled polyurethanes
and other materials incidental to said at least one recycled
component are from a vehicle.
19. The process of claim 14, wherein said recycled polyurethanes
and other materials incidental to said at least one recycled
component are vehicle headliners.
20. The process of claim 14, wherein said recycled polyurethanes
are selected from the group consisting of recycled polyisocyanurate
foam, recycled insulated foam panels, recycled energy absorbent
panels, recycled vehicle headliners, and mixtures thereof.
21. The process of claim 14, wherein said materials incidental to
said at least one recycled component are selected from the group
consisting of composite resins, cloth, adhesives, fiberglass,
plastics, and mixtures thereof.
22. The process of claim 14, wherein said mat is pressed at
temperatures from about 40.degree. C. to about 185.degree. C.
23. The process of claim 14, wherein said mat is pressed with a
pressure of about 5 kg/cm.sup.2 to about 45 kg/cm.sup.2.
24. The process of claim 14, wherein said surface layers are
composed of particles about 1.5 millimeters or less in
diameter.
25. The process of claim 14, wherein said core is composed of
particles about 3 millimeters or less in diameter.
26. The process of claim 14, wherein said isocyanate is
diphenylmethane diisocyanate.
27. A composite panel comprising: a core composed of approximately
40% to 80% polyurethanes milled to particles not larger than
approximately 3 millimeters in diameter; and two surface layers on
the outer surfaces of said core composed of approximately 20% to
60% polyurethanes milled to particles not larger than approximately
1.5 millimeters in diameter, wherein said core and said surface
layers are each blended with isocyanate and water, formed into a
three layer mat and compressed together.
28. The composite panel of claim 27, wherein said polyurethanes are
recycled polyisocyanurate foams.
29. The composite panel of claim 27, wherein said polyurethanes are
recycled insulated foam panels.
30. The composite panel of claim 27, wherein said polyurethanes are
recycled energy absorbent panels.
31. The composite panel of claim 27, wherein said polyurethanes are
from a vehicle.
32. The composite panel of claim 27, wherein said polyurethanes are
from vehicle headliners.
33. The composite panel of claim 27, wherein said polyurethanes are
selected from the group consisting of recycled polyisocyanurate
foams, recycled insulated foam panels, recycled energy absorbent
panels, recycled vehicle headliners, and mixtures thereof.
34. The composite panel of claim 27, further comprising other
materials incidental to at least one recycled component wherein
said other materials are selected from the group consisting of
composite resins, cloth, adhesives, fiberglass, plastics, and
mixtures thereof.
35. The composite panel of claim 27, wherein said binding agent is
isocyanate.
36. The composite panel of claim 27, wherein said binding agent is
diphenylmethane diisocyanate.
37. The composite panel of claim 27, wherein said core and said
surface layers are compressed together by a pre-press and a main
press utilizing temperatures ranging from approximately 40.degree.
C. to 185.degree. C., at a speed of approximately 10 to 16 seconds
per millimeter thickness of the panel, and at a pressure range of
approximately 5 kg per sq. cm. to about 45 kg per sq. cm, or a
continuous belt press system with similar temperatures, pressures,
and speeds.
38. The composite panel of claim 27, wherein said panel is pressed
at temperatures from about 40.degree. C. to about 185.degree.
C.
39. The composite panel of claim 27, wherein said panel is pressed
with a pressure of about 5 kg/cm.sup.2 to about 45 kg/cm.sup.2.
Description
FIELD OF INVENTION
[0001] The invention relates generally to a process for the
manufacture of a three-layer composite panel with improved moisture
resistance, minimal thickness swell, thermal stability, and a
smooth hard surface suitable for direct lamination. The invention
also relates to the composite panel produced by the process. The
composite panel is produced utilizing primarily recycled rigid and
semi rigid polyurethane foams, preferably obtained from vehicle
headliners, insulated foam panels, energy absorbent panels,
polyisocyanurate foam bun stock along with materials incidental to
at least one recycled component, including composite resins, cloth,
adhesives, fiberglass and plastics. The composite panel is composed
of a core layer and two surface layers that are bonded in a
press.
BACKGROUND OF THE INVENTION
[0002] Composite panels and boards are known in the industry. For
example, medium density fiberboard, high density fiberboard and
hardboard are well known. There are many uses for these boards. In
respect of flooring, boards of this type have been used as a
carrier board for decorative laminate. The boards or panels are
also used in the furniture and building industry.
[0003] A finished laminated flooring plank typically consists of
four layers, a homogenous wood based board with a decorative layer
and a clear wear protection layer on top, and a bottom layer or
backer layer to equalize surface tension. The decorative layer is
often designed to make the panel resemble wood. The two basic
lamination processes are either high-pressure lamination (HPL) or
direct lamination (DL). Currently, laminate flooring is not
generally used for commercial application or in residential areas
such as kitchens and bathrooms, due to the thickness swell of
fiberboard when exposed to moisture. Water absorption tends to
cause thickness swell of the fiberboard and often results in
de-lamination and warping.
[0004] There are a variety of polyurethane foams, including
flexible, semi-rigid and rigid foams. Polyurethane products are
produced by the reaction of a polyisocyanate and a
hydroxyl-containing material. A broad spectrum of materials can be
produced to meet the needs of specific applications due to the
variety of diisocyanates and the wide range of polyols that can be
used to produce polyurethane. Most foamed polyurethanes, unlike
thermoplastic materials, cannot be melted and reused in its
original form.
[0005] Rigid polyurethane foams are used primarily for energy
management as insulation for buildings, water heaters, refrigerated
transport, and commercial and residential refrigeration. Rigid
polyurethane foams are also used in construction, appliances,
packaging, tanks and pipes, transportation, marine applications,
and decorative products. Semi-rigid and flexible polyurethane foams
are used as a backing for carpet and in upholstered furniture,
mattresses, and automobiles.
[0006] Product recycling, due to ecological concerns, is becoming
more important worldwide. Polyurethane materials are used in many
vehicle components, including headliners, which cover the interior
roof of the vehicle. Headliners typically consist of layers of
fabric, shock absorbent polyurethane foams, insulating foams and
fiberglass backers.
[0007] Previous attempts have been made to manufacture a
homogeneous board for laminated flooring applications from recycled
polyurethane materials. These boards do not include recycled
vehicle headliners. These homogeneous boards were not fabricated
using a three-layer construction, did not have a closed, non-porous
smooth surface layer, and therefore were suitable only for high
pressure lamination, but not for direct lamination.
[0008] Previous attempts have also been made to form a board from
recycled plastic. Some other processes incorporated a mixture of
wood and recycled plastic. One known panel uses recycled plastic as
a core, sandwiched between layers of cellulose material, such as
aspen wafers. This panel uses a mix of recycled plastics from
interior seating and covers, headliner, trim and padding
components, floor mats, seat divider console, exterior front and
rear fascia grill, plastic lighting assemblies, trunk and floor
padding components of a vehicle. This panel exhibited a significant
drop in modulus of rupture when compared to an aspen wafer panel
without a plastic core.
[0009] The only three layer panel, mentioned above, includes layers
of a wood (cellulose) base. Therefore, none of the methods of
manufacture or boards mentioned above describe a three layer
composite panel made from recycled, non-organic components with a
reduced thickness swell and a closed, non-porous smooth surface
suitable for direct lamination. Accordingly, there is a need in the
art for a three layer composite panel comprised primarily of
recycled polyurethanes along with other materials incidental to the
recycled materials with improved moisture resistant properties and
a closed, non-porous smooth surface suitable for direct
lamination.
SUMMARY OF THE INVENTION
[0010] The current invention satisfies the above needs by providing
a composite panel comprising a core composed primarily of recycled
polyurethanes along with other materials incidental to the
components being recycled and two surface layers on either side of
said core composed primarily of recycled polyurethanes along with
other materials incidental to the components being recycled,
wherein the core and the surface layers are each blended with a
binding agent and water and compressed together to form a three
layer composite panel.
[0011] In a preferred embodiment of the invention a process of
manufacturing a composite panel from recycled polyurethanes and
other materials incidental to the component being recycled is
disclosed. The process comprises the steps of producing a core
layer comprising the steps of cutting and milling recycled
polyurethanes along with other materials incidental to at least one
recycled component, passing the milled polyurethanes and other
materials incidental to the recycled component through a screen to
ensure all particles are not larger than about 3 millimeters in
diameter, blending the recycled polyurethanes and other materials
incidental to the recycled component with isocyanate and water and
cleaning the recycled polyurethanes and other materials incidental
to a recycled component in a wind sifter. The surface layer is
produced by the steps of cutting and milling recycled polyurethanes
and other materials incidental to at least one recycled component,
and blending the recycled polyurethanes and other materials
incidental to the recycled component with isocyanate and water;
cleaning the recycled polyurethanes and other materials incidental
to a recycled component in a wind sifter, passing the milled
polyurethanes and other materials incidental to the recycled
component for the surface layer through a screen to ensure all
particles are not larger than about 1.5 millimeters in diameter.
The composite panel is then formed into a three layer mat with the
blended core layer and the blended surface layers wherein the
surface layers are on either side of the core layer and pressing
the mat with a press at temperatures from about 40.degree. C. to
about 185.degree. C. at a speed of about 10-16 seconds per
millimeter of mat thickness with a pressure of about 5 kg/cm.sup.2
to about 45 kg/cm.sup.2.
[0012] Therefore, it is an object of the present invention to
provide a composite panel with three layers for use in areas with
high moisture comprising a core composed of at least 60% recycled
polyurethanes and other materials incidental to the recycled
component milled to particles not larger than approximately 3
millimeters in diameter and two surface layers on the outer
surfaces of the core composed of at least 40% polyurethanes and
other materials incidental to the recycled component milled to
particles not larger than approximately 1.5 millimeters in
diameter, wherein the core and the surface layers are each blended
with isocyanate and water, formed into a three layer panel and
compressed together.
[0013] These and other objects, features, and advantages of the
present invention may be better understood and appreciated from the
following detailed description of the embodiments thereof, selected
for purposes of illustration and shown in the accompanying
drawings.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a cross sectional view of the composite panel.
[0015] FIG. 2 is a production diagram.
[0016] FIG. 3 is a production diagram.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1, the composite panel is made up of three
layers: a core layer 1 and two surface layers 2. The core layer 1
is made primarily of recycled polyurethanes, which comprises a
blend of recycled car headliners, recycled insulated foam panels
and/or recycled polyisocyanurate foam. Optionally, the core 1 may
be composed of recycled polyurethanes from just one source of
recycled car headliners, recycled insulated foam panels or recycled
polyisocyanurate foam. The core layer 1 also contains other
materials incidental to the recycled components being used and the
recycling process. Such materials incidental to the recycled
components consist of various materials that are found in the
recycled component. For instance, if the source of polyurethane is
vehicle headliners, the incidental materials are the other
components found within a vehicle headliner. These other materials
may include composite resins, cloth, adhesives, fiberglass,
plastics, and other materials.
[0018] The two surface layers 2 are a blend of recycled energy
absorbent panels, recycled insulated foam panels and/or recycled
polyisocyanurate foam. Similar to the core layer 1, the two surface
layers 2 may be optionally composed of recycled polyurethane from
just one source of recycled energy absorbent panels, recycled
insulated foam panels or recycled polyisocyanurate foam. The
surface layers 2 also contain other materials incidental to the
recycled components being used and the recycling process. These
other materials may include composite resins, cloth, adhesives,
fiberglass, plastics, and other materials.
[0019] The entire composite panel is comprised of 40-80% core layer
1 and 20-60% surface layers 2, wherein each surface layer 2
comprises about 10-30% of the panel. In the preferred embodiment,
the entire composite panel is comprised of approximately 60% core
layer 1 and 40% surface layers 2, wherein each surface layer 2
comprises about 20% of the panel. The surface layers 2 are closed,
non-porous smooth surfaces suitable for direct lamination or
bonding of other materials to the surface layers 2.
[0020] The raw materials used in the manufacturing process are
recycled material from vehicle headliners, insulated foam panels,
energy absorbent foam panels and/or polyisocyanurate foam. Other
raw materials that could be used as filler include carpet fiber,
wood flour, and waste paper. In addition to polyurethanes, the raw
materials contain other materials incidental to the recycled
components being used and the recycling process. These other
materials may include composite resins, cloth, adhesives,
fiberglass, plastics, and other materials.
[0021] Referring to FIG. 2 and FIG. 3, shown is the preferred
embodiment for the process for producing core layer materials,
which comprises several steps. First, recycled polyurethanes along
with other materials incidental to the recycled component are cut
and milled in step 3. Then the milled polyurethanes and other
materials incidental to a recycled component are passed through a
screen to ensure all particles are not larger than about 3
millimeters in diameter in step 4. In step 5, the recycled
polyurethanes and other materials incidental to the recycled
component are blended with isocyanate and water. Next, the recycled
polyurethanes and other materials incidental to a recycled
component are cleaned in a wind sifter in step 8.
[0022] Surface layers are produced utilizing a similar process used
to form core layers. First, the recycled polyurethanes and other
materials incidental to the recycled component are cut and milled
in step 6. Then, in step 7 the recycled polyurethanes and other
materials incidental to the recycled component are blended with
isocyanate and water. Next, the recycled polyurethanes and other
materials incidental to a recycled component are cleaned in a wind
sifter in step 9. In step 10, the milled polyurethanes and other
materials incidental to the recycled component for the surface
layer are passed through a screen to ensure all particles are not
larger than about 1.5 millimeters in diameter. Preferably, the
particles intended to be used on the surface layer are 1.5
millimeters in diameter or smaller.
[0023] As shown in FIG. 2 and FIG. 3, the preferred embodiment of
the process, the recycled polyurethane materials are prepared by
individually processing at least one type of recycled component
through cutting and milling machines in step 3 and 6. The raw
materials are gravimetrically metered and blended in a centrifugal
blending chamber in steps 5 and 7. All material is stored
separately in metering silos and a microprocessor weighing system
controls the uniformity from batch to batch.
[0024] A combination of isocyanate and water is used as a binding
agent in the blending process as shown in steps 5 and 7. The
isocyanate is preferably diphenylmethane diisocyanate. The volume
of isocyanate used ranges from 3 to 10% by weight. The volume of
water used ranges from 1 to 9% by weight.
[0025] The panel is formed in step 11 by a three layer forming
station that forms a core layer and two equal smooth outer face
layers. The forming station includes conveyors, metering bins,
spreader heads Gamma-Ray density control units and matching control
and management systems. The conveyors carry the panel to the
presses. As shown in FIG. 2, in step 12 & 13, pressing is
performed by a pre-press and a main press utilizing temperatures
ranging from 40.degree. C. to 185.degree. C., at a speed of 10 to
16 seconds per millimeter thickness of the panel, and at a pressure
range of about 5 kg per sq. cm. to about 45 kg per sq. cm. As shown
in FIG. 3, optionally a continuous belt press system 14 with
similar temperatures, pressures, and speeds can be used. The
hydraulic systems and controls of standard industrial presses,
which are typically used in the wood based composite panels
industry, have to be modified to allow for the specific pressure
modulations required during the press cycle of manufacturing the
composite panels of the invention
[0026] The composite panel of the invention may be used for
interior floors and wall panels. The composite panels may be
laminated or have other surface finishes. The composite panel of
the current invention may be used for various interior or exterior
applications. Exterior uses include signs, billboards, and other
applications requiring a smooth surface, high moisture resistance
and thermal stability.
[0027] The composite panels of the invention exhibit superior
properties when tested with other panels currently used for
flooring. One test involved a determination of linear thermal
expansion. The composite panel of the invention with a laminate
surface was compared to a laminated engineered wood (HDF) flooring
sample and a hardwood flooring sample. The test determined the
linear expansion of movement of the material when exposed to
varying temperature conditions. The samples were acclimated for 48
hours to laboratory conditions of 70.degree. F. and 50% Relative
Humidity ("RH"). The samples were gauged for size and then exposed
to cold acclimation of 0.degree. F. for 48 hours. The samples were
measured again and subjected to 140.degree. F. for 48 hours. The
samples were re-gauged and acclimated again to laboratory
conditions and measured for the final time. The results show all
measurements, two in each direction on each sample, from the stages
as described and calculations were made to show changes to the
samples in inches. TABLE-US-00001 TABLE I Composite panel of
invention with laminate surface Composite panel of invention with
laminate (in inches) Width 1 Width 2 Length 1 Length 2 Conditioned
70.degree. F. 12.012 12.016 12.020 12.005 50% RH Cold acclimation
0.degree. F. 12.008 12.013 12.017 12.003 Hot acclimation
140.degree. F. 12.007 12.011 12.007 11.993 Conditioned 70.degree.
F. 12.007 12.011 12.007 11.993 50% RH Max change during test -0.005
-0.005 -0.013 -0.012 Change after -0.005 -0.005 -0.013 -0.012
completion of test Change from 0.degree. F. to -0.001 -0.002 -0.010
-0.010 140.degree. F.
[0028] TABLE-US-00002 TABLE II Hardwood flooring sample Hardwood
flooring (in inches) Width 1 Width 2 Length 1 Length 2 Conditioned
70.degree. F. 3.135 3.138 12.637 12.344 50% RH Cold acclimation
0.degree. F. 3.135 3.138 12.369 12.347 Hot acclimation 140.degree.
F. 3.130 3.133 12.350 12.326 Conditioned 70.degree. F. 3.135 3.138
12.360 12.337 50% RH Max change during test -0.005 -0.005 -0.032
-0.018 Change after completion 0.000 0.000 -0.023 -0.007 of test
Change from 0.degree. F. to -0.005 -0.005 -0.019 -0.021 140.degree.
F.
[0029] TABLE-US-00003 TABLE III Engineered Wood (HDF) Laminate
flooring Engineered wood (in inches) Width 1 Width 2 Length 1
Length 2 Conditioned 70.degree. F. 11.615 11.615 11.740 11.741 50%
RH Cold acclimation 0.degree. F. 11.613 11.613 11.737 11.739 Hot
acclimation 140.degree. F. 11.597 11.596 11.717 11.718 Conditioned
70.degree. F. 11.597 11.596 11.720 11.720 50% RH Max change during
test -0.018 -0.019 -0.023 -0.023 Change after completion -0.018
-0.019 -0.020 -0.021 of test Change from 0.degree. F. to -0.016
-0.017 -0.020 -0.021 140.degree. F.
[0030] As shown above, the composite panel of the invention
withstood the changes in temperature with the least amount of
change in size. This is particularly important in flooring
materials. Any change is size of a floorboard will cause the
laminate surface to be destroyed by bubbling, warping or peeling or
may cause the actual floorboard to warp causing an uneven surface
and delamination.
[0031] Other testing of the composite panel of the invention showed
superior properties according to standards set forth by the North
American Laminated Flooring Association (NALFA). The NALFA 3.6
Small Ball (Dart) Impact resistance test measures the ability of
laminate flooring to resist fracture due to impact by a small
diameter ball/dart (25 grams) falling onto the surface of the
unrestricted laminate floor sample. Drops are conducted in
incremental heights until the surface of the material is fractured.
The panel was tested using proper underlayment. The composite panel
of the invention met the NALFA specified requirement for light
commercial use.
[0032] Also performed was the NALFA 3.5 Large Ball Impact
Resistance Test. This test measures the ability of laminate
flooring to resist fracture due to impact by a large diameter
ball/dart (25 grams) falling onto the surface of the unrestricted
laminate floor sample. Drops are conducted in incremental heights
until the surface of the material is fractured. The composite panel
of the invention was tested using the proper underlay material. The
composite panel of the invention met the NALFA specified
requirement for heavy commercial use.
[0033] The NALFA 3.2 Thickness Swell test was performed on the
composite panel of the invention. The test measures the ability of
laminate flooring to resist edge thickness increases after being
exposed to distilled water. Two 6 inch by 6 inch specimens of the
composite panel of the invention were cut and the thickness
calculated using a compressometer. The two samples were submerged
one inch below the water line in 70.degree. F. distilled water for
24 hours and then removed and re-measured. The thickness swell is
calculated as a percentage of the original thickness. When
submitted to these test conditions, the composite panels of the
invention had a 0.004 inch thickness swell.
[0034] The composite panel of the invention was also submitted to
the NALFA 3.1 static load test. The test determines the recovery
properties of laminate floor covering after long term indentation
(24 hours) under a specified load. The test sample is conditioned
to equilibrium at 73.degree. F. and 50% relative humidity. The
initial thickness of the sample is determined using a dial
micrometer with a flat presser foot 0.250 inches in diameter. A
specified load is applied to the sample for 24 hours. After removal
of the load, the sample is allowed to recover for 24 hours. The
sample is re-gauged using the 0.250 inch diameter presser foot. The
difference between the two measurements is reported as the residual
compression. Different loads are used in 250 pound increments
starting at 1,400 pounds and working backwards until the residual
compression is 0.001 inches or less. The composite panel of the
invention withstood 1,160 pounds with a residual compression of
0.001 inch loss (0.4%). The NALFA requires flooring to withstand
1,160 pounds per square inch for heavy commercial use.
[0035] Through testing, it was also concluded that the composite
panel of the present invention has low total Volatile Organic
Compounds ("VOC") emissions, formaldehyde emissions, and total
aldehyde emissions. The composite panel made with recycled
materials will likely meet the allowable Greenguard certification
criteria for all pollutants. The results were obtained through an
environmental chamber test following ASTMD 5116. Analysis was based
on EPA Method IP-B for VOC's by thermal desorption followed by gas
chromatography/mass spectrometry and EPA IP-6A for selected
aldehydes by high performance liquid chromatography. Predicted
concentrations were based on a standard floor usage of 13.1 m.sup.2
in a room with ASHRAE ventilation conditions (32 m.sup.3 in volume
and 0.8 ACH) and assumed decay parameters. The results were as
follows: TABLE-US-00004 TABLE IV Environmental testing of composite
panel 24 hour Results: TVOC HCHO Total Aldehydes (.mu.g/m.sup.2 hr)
(.mu.g/m.sup.2 hr) (.mu.g/m.sup.2 hr) 9.3 18.0 18.0 96 hour
Predicted Concentration Results: TVOC Total Aldehydes
(.mu.g/m.sup.3) HCHO (ppm) (ppm) <1 0.005 0.005
[0036] Accordingly, it will be understood that the preferred
embodiment of the present invention has been disclosed by way of
example and that other modifications and alterations may occur to
those skilled in the art.
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