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TWO (2) Patents and IP for Sale/License for the manufacture of the worlds only solid-core Waterproof Laminate COMMERCIAL Flooring and many other uses in the RV and other industries.


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Posted by Reinhard Kessing under Science & Technology

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RECYCLED POLYURETHANES FIBREBOARD

 

RPF Laminate Floor Panels

RPF Marine Boards

RPF Transport Boards

OFFER TO ACQUIRE

 

 

The RPF Technology and Intellectual Property (IP) are offered for sale

including the rights to the 2009 issued Patent:  US 7,527,865B2,

and

the rights to the second Patent:  US 7,754,120, issued on July 13th 2010.


 

Alternatively to the selling the IP & Patent(s),
Seller may be interested in issuing an
Exclusive License Agreement
or enter into a Partnership
with an established industry partner or investors

SEND OFFERS TO CONTACT ON LAST PAGE

INTRODUCTION OF SELLER – DEVELOPER

- Reinhard H. Kessing, engineer, a German Citizen, with more than thirty-five (35) years of hands-on experience with international composite board manufacturing, machinery and customers around the world. Successfully commissioned large scale projects in the following countries: Albania, Austria, Belgium, Canada, Chile, Colombia, Ethiopia, France, Germany, Ghana, Greece, Italy, Netherlands, S.-Korea, Spain, Sweden, Switzerland, Tunisia, Turkey, USA,  and several (former) U.S.S.R states.

-  Numerous inventions resulted in four (4) patent issues, all of them specific to the composite panels industry.

-    Reinhard Kessing owns and operates the Germany based KESCON Engineering,

founded more than 12 years ago. KESCON Engineering provides comprehensive engineering, consulting

and project management services to clients in the composite panel industries worldwide.

-    In early 2012 , Mr. Kessing founded En-Co Group International Corp. (a Panama Corporation), in which he is CEO & Managing Partner.

The En-Co Group International Corp. is also an Engineering-, Consulting- and Project-Management services company to provide services to clients in the composite panel industries industry, specifically (but not limited to) Latin America.

 

PREFACE

Increasing Polyurethane (PU) waste buildup from industrial manufacturing (ex-factory, virgin material), as well as similar waste materials from EOL (end-of-life) vehicles, scrapped refrigerators, district heating tubes and many other sources are receiving increased attention worldwide as a result of rapidly rising amounts and increasingly tight legislation on its treatment and disposal.

Unlike common “plastics”, PU foam cannot simply be molten and reused as virgin material. As an example, in today’s automobile, we find PU and PUR (= PU-rigid-hard) foams in: bumpers, energy absorbent panels, dashboards, seats, door trims, headliners and so on. Often these materials are bonded to secondary materials (fiberglass, cloth, plastics) and are basically impossible to recycle with commonly developed methods. Numerous publications and research point to the problem: Currently only approx. 10% of all waste PU/PUR is being successfully recycled and reintroduced into new products, the rest ends up in landfills or is being incinerated.

One example report: http://eny.hut.fi/library/publications/tkk-eny/tkk-eny-19.pdf

Reinhard H. Kessing (Developer and Seller of the IP), has developed the RPF board concept based on industry needs for profitable recycling of industrial polyurethane waste materials and the manufacture of a solid-core, waterproof laminated flooring product

 Seller has developed: RECYCLED POLYURETHANES FIBREBOARD (RPF) a product and technology  

(both covered by U.S. patents) that provides a solution to the recycling problem and at the same time produces a high-quality, waterproof, solid-core laminate flooring product. RPF is a 3-layer composite panel, manufactured from recycled polyurethanes (PUR) and other components.  

Independent test results met/exceeded all of the North American Laminated Flooring Association (NALFA) performance requirements for commercial flooring. The unique RPF properties include high moisture resistance, low thickness swell, excellent dimensional stability, and a closed, hard surface suitable for direct lamination.

The RPF product is designed to be used for the commercial sector of the laminate flooring industry, but as a backup, has also been found very attractive as a substitute for marine- and CDX/MDO plywood, for end-uses in boats, tractor trailer doors and school bus flooring as well as for the production of sports flooring systems.

HISTORY

The initial product testing of the RPF product was conducted at the Dieffenbacher laboratories in Europe in 2002, with secondary, multiple testing and product development at the Washington State University (WSU) Materials Testing Laboratory in Pullman during 2003; followed by an additional test series at PAL s.r.l. in Italy, as well as at Berstorff, Loedige and SMRS in Germany. Small-scale production runs were undertaken again at the WSU Lab in 2004, 2005 and 2007, including short-cycle lamination tests at the Dynea Overlay facility in Seattle.

As a result of the long invention period, numerous tests and production trials, the process technology is fully developed and 100% repeatable.

 

Mr. Kessing filed a United States Patent and Trademark Application (Serial No. 11/335,204) on Jan. 19th 2006, a continuation of Pat.-Appl. 11/175,642 filed on July 06th 2005. The product patent was granted on May 05th 2009 (US Patent # 7,527,865 B2 “THREE LAYER COMPOSITE PANEL FROM RECYCLED POLYURETHANES”).  In March 2009, Mr. Kessing applied for another patent (Divisional Appl. # 12/393,015), which specifically protects crucial steps of the manufacturing process of the three-layer RPF panel. The process patent (US 7,754,120,) was issued on July 13th 2010.

Extensive research has concluded, that the installation of a RPF production facility is most suitable in North-America, preferably in the mid-Eastern states, (northernmost: PA, TN, central: NC, SC, and southernmost GA).  For any of those locations, the required raw material sources have been identified and can been secured with long-term contracts. The required machinery for a production plant has been established with vendors (mostly from Europe, partly in the U.S.). Some market- and client relationships have been developed, and a detailed projection on installation- production- and operating cost has been prepared.

THE MARKETS FOR RPF

 

Commercial Laminate Flooring

RPF is a 3-layer composite panel, manufactured from recycled polyurethanes (mainly PUR) and many other components. The independent test results not only meet, but exceed all of the North American Laminated Flooring Association (NALFA) performance requirements for Commercial Flooring. The unique RPF properties include high moisture resistance, low thickness swell, excellent dimensional stability, and a closed, hard surface suitable for direct lamination.

 

According to Floor Covering Weekly, the industry’s trade publication, stated in an earlier issue: “Commercial installations of laminate flooring, particularly light commercial settings such as Retail Outlets, Hair Salons and Medical Offices, increased last year to the tune of 17% - or approx. $91.5 million in sales.  The growth potential for this market is so great that many manufacturers that previously denounced the sub-segment as too troublesome due to potentially faulty installations have now implemented commercial programs.”

This trend is basically still unchanged up to now. As can be extracted from numerous publications, the most widely spread complaint with existing laminate flooring products is the edge thickness swell (“buckling”) of the product after exposure to excessive moisture or water. In comparison, today’s specifications for laminate flooring allow a thickness swell up to 12% (for “heavy- commercial”) and up to 18% (for “residential”), when exposed to water (NALFA Test method). Under similar conditions, RPF swells less than 0.8% (virtually not measurable or visible). As a result, today’s laminate floor coverings are currently not specified by professionals like architects, & builders  for hospitality or commercial applications (hotels, theaters, shopping malls, hospitals, airports, showrooms or other high-load, high-traffic areas) where moisture or spills occur frequently. Equally, the desire of many high-end home owners to continue the same floor covering of a hallway into the bath-, or washroom (wet room) is hampered by the inability of current laminate floors to perform in such environment.

Sample References:

- ANSI/NALFA  LF-01-2008 Product Standards publ. by North American Laminate Flooring Association ©

- GOOGLE: “laminate flooring in bathrooms”

RPF closes this market segment and provides a high-return investment

 

The RPF board can be produced at a relatively low cost (because of 100% recycling content) and high margins, yet it meets all the required performance criteria.  The commercial market sector, unlike the residential market sector, can support a unit cost of $3.50 to $6.00 per square foot. According to Floor Covering Weekly, the commercial sector is the fastest growing segment in the $1.8 billion laminate flooring market.  It is anticipated that this growth will be even greater should a suitable product be available for this sector of the market.


Alternative Uses for RPF Board

The RPF product is primarily designed to be used for the commercial sector of the laminate flooring industry, but due to it’s unique characteristics, strength and durability, has also been found attractive as a substitute for:

 

Ø  Marine and CDX/MDO plywood, for end-uses in boat hulls, tractor trailer doors and school bus flooring

Ø  Production of sports flooring systems.

Ø  Outdoor billboard signs (replacement for plywood)

Ø  Decorative and structural (waterproof) panels for the RV and boat industry

 

 

 

PRODUCT CERTIFICATIONS

A major selling point is the fact that the RPF product is manufactured from 100% post industrial waste material, and the end of life RPF product may also be returned to the RPF plant for recycling.

The RPF developer is convinced that the RPF product will receive the following national environmental certifications:

            Scientific Certification Systems” (SCS); SCS administers the “Green Seal” program, and also certifies products for their recycled or recovered fiber content.

            Green Guard Inc.”; Green Guard offers both the testing and certification program pertaining to chemical emissions emitted from a product, and the volume of such emissions. Testing is done on a regular basis throughout the year, with samples provided by the manufacturer, and with visits by the Green Guard staff to the manufacturer’s location.

            United States Green Building Council” (USGBC); the market for green building materials is being developed primarily by the USGBC, through its Leadership in Energy and Environmental Design (LEED) program.  LEED is a voluntary, consensus program that allows building owners and architects to achieve  “LEED Certification” for projects built in the USA.  The LEED rating system provides for points to be earned on a project and depending on the number of points earned, the owners / architects can apply for one of the levels of LEED certification that will often permit tax rebates and other financial incentives.  Many Federal Agencies, States and Cities are now requiring that all new construction projects achieve LEED certifications.  The RPF product will be eligible to earn LEED points in the following categories:

a)   Indoor Air Quality-Products with no added Urea Formaldehyde

b)   Recycled and/or recovered fiber content

 

LEED certification will greatly assist clients in having their RPF product lines specified by architects and designers.

PRODUCT TESTING

In addition to the tests of RPF board produced by the RPF developer at the Washington State University Testing Laboratory, independent tests were conducted by Air Quality Sciences and the Professional Testing Laboratory Inc., both nationally recognized certification agencies. The test air quality protocols and resulting data demonstrated that the RPF laminated test boards have low total Volatile Organic Compounds, formaldehyde, and very low total aldehyde emissions. Modeling estimates for the samples indicate that the product would meet the criteria for GreenGuard certification. The Professional Testing Laboratory Inc. test results measured the RPF samples based on the North American Laminate Flooring Association specifications and standards. The results obtained demonstrate that the RPF product exceeds the criteria for heavy commercial utilization (Appendix 3).

SUMMARY of RPF-PANEL ADVANTAGES

 

·            Green Product…………….……..RPF will qualify for LEED & Greenguard certification

·            100% recyclabl………...the RPF-FLOOR board can be recycled after it’s service life

·            Formaldehyde Free……...independent test shows “value below quantifiable level”

·            Very low water absorption……...less than 5% (by weight) after 24-h submersion

·            Very low thickness swell….... thickness swell less than 1% after 24-h submersion

·            High Thermal Stability….outperforms MDF, HDF, PB and single-layer natural wood

·            High Screw holding…………..better performance than marine/CDX/MDO plywood

·            Mold & Rot resista..............totally inorganic compounds (no wood, no cellulose)

·            Termite & Insect resistant…...….due to 100% inorganic compounds, high density

·            Custom Design Features……..RPF Panels can be designed to meet specific client requirements

·            Suitable for Direct Lamination…..non-porous, smooth, hard, flat surface allows for lamination of the thinnest, most economical laminates, (if desired),  as well as direct, digital printing process.

·            Longer Life Cycle….........……...virtual water resistance increases product life

·            Highest Point Load capability in it’s class…………..the competition has a hollow core and poor load bearing capabilities at a higher price.

·            Suitable for glue-down installations………opens new markets like hospitals, laboratories, etc.

·            Lower Price………RPF panels can be produced at a lower cost due to 100% recycled materia

 

Intellectual Property Transfer Options

OPTION1:

The RPF developer will consider the sale of the Intellectual Property (IP) and patent rights for the two (2) patents (as mentioned on page 1) to a third party for a fixed, one-time, lump sum.

OPTION2:

The RPF developer will consider a short term option with an investor who is seeking to launch the project, to purchase an exclusive license for the intellectual property, combined with a subsequent royalty payment based on gross production, when the plant commences operations. In such case, the the RPF developer will be able to assist in designing, building and starting-up and commissioning such plant for an additional engineering/consulting fee

For further information and to send an offer, please contact:

Reinhard H. Kessing

Worldwide Mobile (+49) 170 532 3338

or:

kesconus@aol.com

or:

RPFindustries@aol.com