Abstract: A rigid polymeric modular flooring plank that contains chlorinated polyvinyl chloride (CPVC) in the core or base layer. The rigid polymeric modular flooring plank has at least a polymeric core or base layer, a decorative layer, and a wear layer located above the decorative layer. The CPVC can offset the negative effects from any plasticizer present in the core layer, and thus permits the core layer to include plasticized material such as from recycled or reclaimed sources including rework and scrap materials. Methods of making the planks are further described. A method to control dimensional stability of a polymeric flooring plank is further described.

Abstract: A device for making a molded stair tread is described. The device can have: a base; a pivoting assembly; a molding template connected to the pivoting assembly; a holding device connected to the molding template, the holding device having a clamp jaw and a pivot configured to rotate the holding device relative to the molding template; and a locking mechanism configured to hold the molding template and the holding device in an open configuration such that the holding device can accept a first part of the plastic sheet and configured to release the molding template and the holding device such that the holding device is in a securing configuration that secures, via the clamp jaw, the first part of the plastic sheet to the first side of the molding template at the first longitudinal edge of the molding template. Methods for making the stair tread are described as well as the molded stair tread.

Abstract: A rigid polymeric modular flooring plank can be one continuous piece having a top surface, a bottom surface and multiple sides defining the edges of said rigid polymeric modular flooring plank. The rigid polymeric modular flooring plank can include the appearance of multiple tiles or one tile as part of the top surface, with each of the multiple tiles having multiple simulated sides and a decorative surface, and each tile is completely surrounded by simulated grout lines that have a depth and either have a full width W or a half width ½W. Any simulated grout line that is located at any of said multiple sides has the half width and all other simulated grout lines have the full width. The rigid polymeric modular flooring plank has at least a polymeric base layer, a decorative layer, and a wear layer located above the decorative layer.

Abstract: A rigid polymeric modular flooring plank can be one continuous piece having a top surface, a bottom surface and multiple sides defining the edges of said rigid polymeric modular flooring plank. The rigid polymeric modular flooring plank can include the appearance of multiple tiles or one tile as part of the top surface, with each of the multiple tiles having multiple simulated sides and a decorative surface, and each tile is completely surrounded by simulated grout lines that have a depth and either have a full width W or a half width ½W. Any simulated grout line that is located at any of said multiple sides has the half width and all other simulated grout lines have the full width. The rigid polymeric modular flooring plank has at least a polymeric base layer, a decorative layer, and a wear layer located above the decorative layer.

Abstract: A device for making a molded stair tread is described. The device can have: a base; a pivoting assembly; a molding template connected to the pivoting assembly; a holding device connected to the molding template, the holding device having a clamp jaw and a pivot configured to rotate the holding device relative to the molding template; and a locking mechanism configured to hold the molding template and the holding device in an open configuration such that the holding device can accept a first part of the plastic sheet and configured to release the molding template and the holding device such that the holding device is in a securing configuration that secures, via the clamp jaw, the first part of the plastic sheet to the first side of the molding template at the first longitudinal edge of the molding template. Methods for making the stair tread are described as well as the molded stair tread.

Abstract: Adhesive-backed flooring panels, a flooring system including flooring panels, a method of installing flooring panels, a method of manufacturing flooring panels, and a packaged flooring system are provided.

Abstract: A halogenated polysaccharide is provided having a halogen content of from about 1.0 wt. % to about 85 wt. % based on the total weight of the halogenated polysaccharide and having an average chain length of at least 6 monosaccharides. Methods of halogenating a polysaccharide to form a halogenated polysaccharide are provided that can be performed in the presence or absence of a proton solvent. Compositions such as articles of manufacture containing a halogenated polysaccharide and methods of producing such articles are also provided. The article of manufacture can also include one or more additional polymers, for example, polyvinylchloride (PVC). The article of manufacture can be, for example, a flooring tile, flooring plank, or carpet. Halogenated polysaccharides and products containing the same are bio-based, environmentally sustainable replacements or complements to existing polymers and polymer products.

Abstract: A halogenated polysaccharide is provided having a halogen content of from about 1.0 wt. % to about 85 wt. % based on the total weight of the halogenated polysaccharide and having an average chain length of at least 6 monosaccharides. Methods of halogenating a polysaccharide to form a halogenated polysaccharide are provided that can be performed in the presence or absence of a proton solvent. Compositions such as articles of manufacture containing a halogenated polysaccharide and methods of producing such articles are also provided. The article of manufacture can also include one or more additional polymers, for example, polyvinylchloride (PVC). The article of manufacture can be, for example, a flooring tile, flooring plank, or carpet. Halogenated polysaccharides and products containing the same are bio-based, environmentally sustainable replacements or complements to existing polymers and polymer products.

Abstract: Methods and systems for decorating at least one bevel surface or other surface of a laminated flooring are described. The bevel surface can be decorated by non-transfer printing such as digital printing. The digital printer can be an ink jet printer such as a piezoelectric drop-on-demand (DOD) printer that allows a color and pattern to be placed on the bevel surface that matches the print design (décor pattern or face design) of the laminated flooring. Other devices are provided such as a device that takes a picture of or scans an image of the print design, and modifies the taken picture or the scanned image so that the edge pattern thereof matches with an edge pattern of the print design.

Abstract: Methods are described for mechanically scraping surfaces of boards, such as flooring boards, to impart random-looking scraped profiles therein. An apparatus for mechanically scraping boards to form the scraped board products also is described. A board, such as a flooring board, having a random-looking scraped appearance that includes overlapping multiple scrape patterns is described. Boards, such as flooring boards, having a simulated rustic or distressed appearance made with the methods and apparatus also are described.

Abstract: A thermoplastic laminate plank is described wherein the thermoplastic laminate plank comprises a core, a print layer, and optionally an overlay. The core comprises at least one thermoplastic material and has a top surface and bottom surface wherein a print layer is affixed to the top surface of the core and an overlay layer is affixed to the top surface of the print layer. Optionally, an underlay layer can be located and affixed between the bottom surface of the print layer and the top surface of the core. In addition, a method of making the thermoplastic laminate plank is further described which involves extruding at least one thermoplastic material into the shape of the core and affixing a laminate on the core, wherein the laminate comprises an overlay affixed to the top surface of the print layer and optionally an underlay layer affixed to the bottom surface of the print layer.

Abstract: A composition is described that includes at least one polyolefin, at least one thermoplastic bio-resin derived from starch or soy or both, and at least one compatibilizer having at least one polyolefin and at least one polar group. Surface coverings and floor coverings, such as laminated floor coverings, having the composition, are also described.

Abstract: Methods and systems for decorating at least one bevel surface or other surface of a laminated flooring are described. The bevel surface can be decorated by non-transfer printing such as digital printing. The digital printer can be an ink jet printer such as a piezoelectric drop-on-demand (DOD) printer that allows a color and pattern to be placed on the bevel surface that matches the print design (décor pattern or face design) of the laminated flooring. Other devices are provided such as a device that takes a picture of or scans an image of the print design, and modifies the taken picture or the scanned image so that the edge pattern thereof matches with an edge pattern of the print design.

Abstract: A plank, and system and method for joining surface-covering planks, which includes a disengageable connector(s) for detachably connecting multiple planks simultaneously are described. A plank can include a tongue-profiled edge and an opposite rib-profiled edge, and a disengageable connector can have a groove that can be mated with the tongue on one side edge of the plank, and also has a rib-receiving portion that alternatively can be mated with a downward extending rib on the opposite side edge of the plank. The plank can have a variety of designs on the other edges of the plank.

Abstract: Methods and systems for decorating at least one bevel surface or other surface of a laminated flooring are described. The bevel surface can be decorated by non-transfer printing such as digital printing. The digital printer can be an ink jet printer such as a piezoelectric drop-on-demand (DOD) printer that allows a color and pattern to be placed on the bevel surface that matches the print design (décor pattern or face design) of the laminated flooring. Other devices are provided such as a device that takes a picture of or scans an image of the print design, and modifies the taken picture or the scanned image so that the edge pattern thereof matches with an edge pattern of the print design.

Abstract: A thermoplastic laminate plank is described wherein the thermoplastic laminate plank comprises a core, a print layer, and optionally an overlay. The core comprises at least one thermoplastic material and has a top surface and bottom surface wherein a print layer is affixed to the top surface of the core and an overlay layer is affixed to the top surface of the print layer. Optionally, an underlay layer can be located and affixed between the bottom surface of the print layer and the top surface of the core. In addition, a method of making the thermoplastic laminate plank is further described which involves extruding at least one thermoplastic material into the shape of the core and affixing a laminate on the core, wherein the laminate comprises an overlay affixed to the top surface of the print layer and optionally an underlay layer affixed to the bottom surface of the print layer.

Abstract: Surface coverings, such as floor coverings, with an interlocking design are described. Methods of making the surface coverings are further described.

Abstract: A system is provided for creating bevel edges on a plank. In some embodiments, the system comprises two bevel-cutting tools disposed in fixed positions and two guided cylinders disposed to independently move two edges of a plank to within varying degrees of contact with the bevel-cutting tools. Separate controllers can be provided to independently control the time, frequency, and rate of movement of the guided cylinders. Methods are provided for creating the appearance of a hand-scraped wood plank. A method for creating irregular bevel edges on a plank is also provided as are a system and method that use a plank production line operation. A plank having irregular beveled edges and the appearance of a hand-scraped wood plank is also provided.

Abstract: A process for sub-dividing a laminated flooring substrate into a plurality of laminated flooring planks and a system therefore are described. The process can include providing a laminated flooring substrate having a decorative pattern on a core wherein the decorative pattern can include a plurality of indicators, and independently detecting the indicators with a plurality of detecting devices, each assigned a respective indicator. The detecting devices can individually obtain the position of the detected indicators and a control unit can align a separate saw blade per each position detected. The system includes a cutting unit with individually adjustable saws or an alignment device configured to align the laminated flooring substrate with the saws, to cut the laminated flooring substrate along positions relative to the detected indicators, for example, in the center thereof or off-set therefrom.

Abstract: Methods and systems for decorating at least one bevel surface or other surface of a laminated flooring are described. The bevel surface can be decorated by non-transfer printing such as digital printing. The digital printer can be an ink jet printer such as a piezoelectric drop-on-demand (DOD) printer that allows a color and pattern to be placed on the bevel surface that matches the print design (décor pattern or face design) of the laminated flooring. Other devices are provided such as a device that takes a picture of or scans an image of the print design, and modifies the taken picture or the scanned image so that the edge pattern thereof matches with an edge pattern of the print design.