CPC B32B 21/14 (2013.01) [B05D 3/067 (2013.01); B05D 7/06 (2013.01); B05D 7/56 (2013.01); B32B 7/12 (2013.01); B32B 21/08 (2013.01); B32B 27/20 (2013.01); B32B 27/22 (2013.01); B32B 27/304 (2013.01); B32B 27/32 (2013.01); B32B 37/10 (2013.01); B32B 37/1284 (2013.01); B32B 37/144 (2013.01); B32B 37/16 (2013.01); B32B 38/0012 (2013.01); C09D 5/1618 (2013.01); C09D 175/04 (2013.01); B05D 2503/00 (2013.01); B32B 2255/08 (2013.01); B32B 2255/26 (2013.01); B32B 2305/72 (2013.01); B32B 2307/10 (2013.01); B32B 2307/308 (2013.01); B32B 2307/554 (2013.01); B32B 2307/584 (2013.01); B32B 2307/7145 (2013.01); B32B 2307/72 (2013.01); B32B 2307/7265 (2013.01); B32B 2323/04 (2013.01); B32B 2471/00 (2013.01)] | 9 Claims |
1. A method of making a plank, the method comprising:
mixing all constituents in dry powder form into a homogeneous powdered mixture in a blending machine at between 1500 to 3500 RPM for 5 to 10 minutes;
heating the powdered mixture;
extruding the heated powdered mixture under pressure through an adjustable mold at a temperature of between 180° C. and 220° C. in a continuous process to form extruded composite core blank material;
cutting the extruded composite core blank material into a composite core blank of a rectilinear width and length;
allowing the composite core blank to stabilize for 3 to 5 days at a temperature in the range of 18° C. to and including 25° C.;
surface sanding the composite core blank on one surface using sandpaper having a grit number in the range of number 60 to and including number 80;
drying in a kiln a hardwood veneer having a thickness in the range of 0.4 mm to and including 2.0 mm to a moisture content in the range of 6% to and including 12% moisture content by weight;
running an individual rigid composite core blank through a roller-type glue applicator that applies a moisture resistant polyurethane type adhesive at a rate in the range of 60 grams/M2 to and including 160 grams/M2 in response to the hardwood veneer's thickness and species of hardwood;
layering the kiln dried hardwood veneer onto the sanded surface of the composite core blank;
pressing the layer of hardwood veneer and composite core blank in a hydraulic press in a range of 150 psi to and including 250 psi for a period of time in the range of 3 hours to and including 6 hours in response to an ambient temperature that is within the range of 5° C. to and including 35° C. to adhere the layered hardwood veneer and the composite core blank to one another and form a plank;
after the pressing, the plank is palletized and allowed to stabilize for 2-4 days;
after stabilization, the plank is milled to first cut a modified locking tongue-and-groove profile on long sides of the plank, after which a locking profile is formed on short sides of the plank; and
coating the hardwood veneer with a UV catalyzed polyurethane coating having aluminum oxide particles and a silver ion material for antimicrobial control present at a concentration of about 0.3%.
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