ELASTIC FLOORING PRODUCT AND METHOD FOR THE PRODUCTION THEREOF

专利摘要:
Described herein are resilient floor coverings made of vinyl-free materials and methods of making the same. This summary is intended to serve as a scanning tool for the purpose of research in the art and is not intended to be limiting of the present invention.
公开号:BE1025419B1
申请号:E2017/5422
申请日:2017-06-12
公开日:2019-02-14
发明作者:Jeffrey J. Wright；John J.M. Rees；Tom Odum；Jean Briere；Mahesh Subramanian；Jay Vecsey
申请人:Shaw Industries Group, Inc.；
IPC主号:

专利说明:

ELASTIC FLOORING PRODUCT AND METHOD FOR THE PRODUCTION THEREOF
Field of the Invention In one aspect, the invention relates to a resilient flooring, and more particularly to a vinyl-free resilient flooring product.
Background of the Invention Conventional resilient floor coverings are typically made in the form of an endless web or in the form of tiles. Elastic floor covering as a web typically has a floor, thermally stable under or mat layer which is coated with one or more layers of similarly formulated polymer compounds. For aesthetic reasons, a color layer is typically also arranged between the polymer layers and the polymer layers can optionally be chemically or mechanically embossed. Similarly, resilient tiled flooring is typically molded as a laminated composite structure having a base layer, a decorative layer attached to the base layer, a protective film layer disposed on the decorative layer, and a topcoat disposed on the protective film layer , For aesthetic reasons, the tile can also be mechanically embossed in order to convey a desired surface structure or pattern.
Currently, both conventional elastic sheet and tile flooring use vinyl polymers such as Polyvinylchloride plastisols, polyvinylchloride homopolymers, and polyvinylchloride acetate resin, as
Main component in the various sub and composite layers described above. However, these conventional vinyl flooring systems have some known disadvantages. For example, the long-term appearance of an installed resilient floor depends on its dimensional stability, which refers to the ability of the tile or sheet to maintain its original dimensions and resist shrinkage over the life of the flooring. This means that conventional vinyl polymers are unable to provide the dimensional stability or dimensional stability necessary to achieve an acceptable level
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To preserve the long-term appearance and the useful life of an installed elastic floor. In order to improve the dimensional stability or surface stability, various chemical stabilizers and fiber-based additives, which include synthetic fibers, fillers, binders, resin and glass, were built into these polymer systems. Unfortunately, these additives and stabilizers also lead to an increased price of the end product. However, increasing the filler concentration not only increases the dimensional stability, but is also a recognized means of improving fire suppression, thermal insulation and also the sound-absorbing properties of the floor covering. Unfortunately, vinyl polymers are known to have limited flex and impact resistance properties when the concentration of additives such as fillers and fibers is increased.
In addition, the installation of resilient flooring typically requires the use of an adhesive to secure the flooring to the underlying floor structure. Many conventional commercial adhesives are chemically incompatible with vinyl polymers and in some cases will not provide the necessary adhesion. In even more extreme cases, certain adhesives will react chemically with the vinyl polymers, resulting in complete degradation of the resilient flooring. It has therefore become necessary to provide specially formulated adhesives that are chemically compatible with the conventional elastic vinyl flooring that does not degrade over time. Understandably, this creates additional installation expenses, which are desirably avoided. Furthermore, in many cases, incompatible adhesives will be present on an existing floor and will need to be removed or a sealant applied to achieve acceptable adhesion to the vinyl flooring.
Elastic flooring also has a limited life and will have to be replaced at some point, the resulting used flooring usually being sent to the landfill. The huge amount of flooring waste that accumulates annually puts a strain on the landfill capacity and has a negative impact on the environment. Around
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BE2017 / 5422 To reduce the impact of used resilient flooring on the environment and to recover some of the financial loss due to the disposal of useful waste material, the recycling of resilient flooring would appear to be a logical solution. In addition, the cost of grinding and remixing these resins is usually prohibitive when compared to the much lower cost of brand new vinyl resins.
[0006] Lastly, and perhaps most importantly, there are significant health and safety concerns associated with the use of vinyl polymer systems in resilient flooring systems. As noted above, vinyl flooring products often contain additional chemicals to alter the chemical or physical properties of the product. For example, phthalate plasticizers are traditionally added to make PVC systems more elastic. There are concerns that these additives will wash out of vinyl products over time. In addition, there are concerns that vinyl floor coverings can release harmful gases into the air over time, especially if they are burned. Some studies suggest that this outgassing can contribute to health complications. Given these concerns, certain jurisdictions are now considering legislation that mandates the use of certain vinyl polymers such as Would ban PVC in various consumer goods due to the threats they pose to human and environmental health.
Given these drawbacks, some in the flooring industry have begun to look for suitable replacements for conventional vinyl systems in the manufacture of resilient flooring. An alternative is to use ordinary thermoplastic polyolefins.
Various methods are available to apply polyolefin backing materials that include powder coating, hot melt application, and extruded film or foil lamination. However, using ordinary polyolefins can also present difficulties. For example, ordinary ones
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Polyolefin resins insufficient adhesion to use them in elastic flooring construction. In addition, common polyolefins have relatively high application viscosities and relatively high heat requirements. This means that common thermoplastic polyolefins are characterized by having relatively high melt viscosities and high recrystallization and solidification temperatures. Even common elastomeric polyolefins, i.e. Polyolefins which have low crystal inities usually have relatively high viscosities and relatively high recrystallization temperatures.
One method to overcome the viscosity and recrystallization deficiencies of ordinary polyolefins is to formulate the polyolefin resin as a hot melt, which is usually associated with low molecular weight polyolefins containing waxes, tackifiers, various flow modifiers, and / or other elastomers Materials are formulated. Unfortunately, hot melt systems can require substantial formulation and yet often achieve insufficient gap strengths. The most significant shortcoming of a typical hot melt system, however, is its melt strength, which is usually too low to allow use in a direct extrusion coating process.
As such, polyolefin hot melt systems are typically used in relatively slow, less efficient processes, such as using heated doctor blades or rotating melt transfer rolls.
Although unformulated high pressure low density polyethylene (LDPE) can be used in a conventional extrusion coating process, LDPE resins typically have poor elasticity which can lead to excessive stiffness. Conversely, such ordinary polyolefins which have improved elasticity, e.g. Ultra-low-density polyethylene (ULDPE), which still does not have sufficient elasticity, has extremely low melt strengths and / or have a tendency to resonate during extrusion coating. To overcome extrusion coating difficulties, ordinary ones
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Polyolefins with sufficient elasticity are used in lamination processes; However, lamination processes are typically expensive and can lead to extended production rates compared to direct extrusion coating processes.
[0011] There remains a need for resilient floor coverings that do not contain vinyl polymers. In other words, it would be desirable to provide a vinyl-free resilient flooring that can be made in a manner and with equipment that is similar to that used to make conventional vinyl resilient flooring. Similarly, there is still a need for vinyl-free resilient flooring that provides dimensional stability and adequate flexural strength and impact properties, regardless of the concentration of inorganic filler that may be present. Still further, there is a need for vinyl-free resilient flooring that is capable of being recycled with greater ease than conventional vinyl flooring products. Finally, there is also a need for vinyl-free elastic flooring, which is considered safe without being associated with health and public safety concerns for the environment.
SUMMARY In accordance with the purpose (s) of the invention as set forth and described in detail herein, the invention in one aspect relates to vinyl-free resilient flooring.
In an exemplary aspect, an elastic floor covering is disclosed herein that includes a support member having a top surface and an opposite bottom surface that is configured to substantially rest against the floor when the elastic floor covering is placed in a selected orientation, and wherein the carrier part has at least one carrier layer, the at least one carrier layer of the carrier part having a carrier composition which has polyolefin elastomers and a filler; a decorative part having a top surface and an opposite bottom surface, the decorative part being formed
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BE2017 / 5422 is that it lies above the carrier part such that the top surface of the carrier part is in contact with the bottom surface of the decorative part, and wherein the decorative part has a layer of paint; and a wear layer having an exposed outer surface portion that is designed for exposure to the environment and an opposite lowermost surface that is designed to lie substantially over the decorative part of the flooring, the wear layer having an abrasion resistance of more than 5000 cycles when measured according to ASTM D3884 under test conditions that have an H18 wheel, 1000 gram load, and cleaned every 300 cycles; wherein the exposed outer surface of the wear layer has a micro-scratch resistance, which is characterized by a change in gloss value in the range from 1 to 3, measured according to Martindale test EN 16094-2012 test A (MSR-A) or test B (MSR-B) by visual Judgment on surface scratching; and wherein the resilient floor covering has no vinyl polymer material.
[0014] In a further exemplary aspect, an elastic floor covering is disclosed herein, which has a carrier part with a top surface and an opposite bottom surface, which is designed to lie substantially against the floor when the elastic floor covering is placed in a selected orientation, and wherein the carrier part has at least one carrier layer, the at least one carrier layer of the carrier part having a carrier composition which has polyolefin elastomers and a filler; a decorative part having an uppermost surface and an opposite lowermost surface, the decorative part being formed so that it lies above the carrier part such that the uppermost surface of the carrier part is in contact with the lowermost surface of the decorative part, and wherein the decorative part has a layer of paint; and has a wear layer with an exposed outer surface portion configured for exposure to the environment and an opposite lowermost surface configured to substantially overlie the decorative portion of the flooring, the resilient flooring having a short term residual impression behavior in the area from 0 inches to 0.09 inches, measured according to ASTM F1914 under the conditions: 10
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Minutes of exercise with 140 lb., 60 minutes of recovery; and wherein the resilient floor covering has no vinyl polymer material.
[0015] In a further exemplary aspect, an elastic floor covering is disclosed herein, which has a support part with a top surface and an opposite bottom surface, which is designed to lie substantially against the floor when the elastic floor covering is placed in a selected orientation, and wherein the carrier part has at least one carrier layer, the at least one carrier layer of the carrier part having a carrier composition which has polyolefin elastomers and a filler; a decorative part having an uppermost surface and an opposite lowermost surface, the decorative part being formed so that it lies over the support part such that the upper surface of the support part is in contact with the lowermost surface of the decorative part, and wherein the decorative part has a layer of paint; and a wear layer having an exposed outer surface portion configured for exposure to the environment and an opposite lowermost surface designed to overlie substantially the decorative portion of the flooring, the exposed outer surface portion of the wear layer further comprising a scratch layer ; and wherein the resilient floor covering has no vinyl polymer material.
[0016] In a further exemplary aspect, an elastic floor covering is disclosed herein, which has a carrier part with a top surface and an opposite bottom surface, which is designed to lie substantially against the floor when the elastic floor covering is placed in a selected orientation, and wherein the carrier part has at least one carrier layer, the at least one carrier layer of the carrier part having a carrier composition which has polyolefin elastomers and a filler; a decorative part having an uppermost surface and an opposite lowermost surface, the decorative part being formed so that it lies above the carrier part such that the uppermost surface of the carrier part is in contact with the lowermost surface of the decorative part, and wherein the decorative part has a layer of paint; and a
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Wear layer having an exposed outer surface portion which is designed for exposure to the environment and an opposite lowermost surface which is designed to lie substantially over the decorative part of the flooring, the resilient flooring having a dimensional stability of less than about 0, 17% shows determined by ASTM F2199-0 at 82 ° C and 24 hours; and wherein the resilient floor covering has no vinyl polymer material.
[0017] Also disclosed here are methods for making the resilient floor coverings disclosed herein.
BRIEF DESCRIPTION OF THE FIGURES These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended figures, in which:
Figure an exemplary structure of the vinyl-free
Flooring product according to the present invention shows.
[0020]
Figure 2 shows an exemplary structure of the vinyl-free
Flooring product according to the present invention shows.
[0021]
Figure 3 shows an exemplary structure of the vinyl-free
Flooring product according to the present invention shows.
[0022]
Figure 4 shows an exemplary structure of the vinyl-free
Flooring product according to the present invention shows.
Figure 5 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
Figure 6 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
Figure 7 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
Figure 8 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
2017/5422 g BE2017 / 5422 [0027] FIG. 9 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
Figure 10 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
Figure 11 shows an exemplary manufacturing procedure for producing the vinyl-free flooring product according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION The present invention can be more readily understood by reference to the following detailed description, examples, drawing and claims, and the foregoing and following description. However, before the present articles, devices, systems, and / or methods are disclosed and described, it should be understood that this invention is not limited to the specific articles, devices, systems, and / or methods disclosed unless otherwise specified , as this can of course vary. It is also to be understood that the terminology used herein is for the purpose of describing certain aspects only and is not intended to be limiting.
[0031] The following description of the invention is provided as one practicable teaching of the invention in its best known form. In addition, those skilled in the art will recognize and understand that many changes can be made to the various aspects of the invention described herein while still retaining the beneficial results of the present invention. It will also be apparent that some of the desired advantages of the present invention can be obtained by selecting some of the properties of the present invention without using other properties. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the present invention are possible and even desirable in certain circumstances and are part of the present invention. Therefore, the following description is used to illustrate the
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Principles of the present invention and not provided as a limitation thereof.
In this description and in the claims that follow, reference is made to a number of terms to be defined so that they have the following meanings:
Throughout the description and claims of this specification, the word include / include and other forms of the word, for example comprising / having and including / including, including, but not limited to, and is not intended to be, for example, other additions To exclude components, integers, or steps.
[0034] The singular forms, one, one and that, as used herein, include the plural references unless the context clearly dictates otherwise. Therefore, e.g. a reference to “a layer two or more such layers, unless the context indicates otherwise.
[0035] Ranges may be expressed herein as from about a certain value, and / or up to about another certain value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as an approximation using the reference word, for example, it should be understood that the particular value is another aspect. It is further understood that the endpoints of each area are significant both in relation to the other endpoint and independently of the further endpoint.
[0036] The terms optional or optional, as used herein, mean that the subsequent event or circumstance described may or may not occur, and that the description includes cases where the event or circumstance occurs and cases where / he doesn't enter.
[0037] As used herein, the term essentially means that the event or circumstance described below occurs entirely, or
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BE2017 / 5422 that the event or circumstance described below generally, typically, approximates or occurs. For example, if the description reveals that substantially all of the active ingredient is released, one of ordinary skill in the art will readily understand that the active ingredient need not be fully released. Rather, this term conveys to a person skilled in the relevant field that the active ingredient only has to be released to an extent so that an effective amount is released.
Elastic flooring In various aspects, the present invention relates to elastic flooring. In one aspect, the invention relates to an elastic floor covering configured for placement on a floor in a selected orientation. In one aspect, and with reference to FIG. 1, the resilient floor covering may have a support part, a decorative part, and a wear layer. In a still further aspect, the elastic floor covering can optionally have at least one connecting layer (binding layer). In yet another aspect, the resilient floor covering has no vinyl polymer material.
In one aspect, the resilient floor covering may be a support member having a top surface and an opposing bottom surface that is configured to substantially abut the floor when the resilient floor covering is placed in a selected orientation, and wherein the support member is at least one Carrier layer, wherein the at least one carrier layer of the carrier part has a carrier composition having polyolefin elastomers and a filler; a decorative part having an uppermost surface and an opposite lowermost surface, the decorative part being formed so that it lies above the carrier part such that the uppermost surface of the carrier part is in contact with the lowermost surface of the decorative part, and wherein the decorative part has a layer of paint; and have a wear layer with an exposed outer surface portion configured for exposure to the environment and an opposite lowermost one
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Surface which is designed to lie essentially over the decorative part of the floor covering. In another aspect, the exposed outer surface portion of the wear layer may further include a scratch layer.
Support part In one aspect, the support part of the elastic floor covering can have a lowermost surface or underside and an opposite uppermost surface or top. In this aspect, the lowermost surface of the support member can be configured to substantially abut the floor when the resilient flooring is placed in the selected orientation. In a further aspect, the carrier part can have at least one carrier layer. It is contemplated that a backing layer of the at least one backing layer may define the lowermost surface of the backing member. It is further contemplated that a backing layer of the at least one backing layer may define the top surface of the backing member. In some aspects, the at least one backing layer may have a single backing layer. In further aspects, the at least one carrier layer can have a multiplicity of carrier layers.
[0043] In one aspect, the at least one carrier layer of the carrier part can have one or more first carrier layers and a secondary carrier layer. For example, in a further aspect, the at least one carrier layer of the carrier part can have a first carrier layer, a second carrier layer, and a secondary carrier layer. In yet another aspect, the secondary support layer can define the lowermost surface of the support member, and the first and second support layers can be configured to lie substantially over the secondary support layer.
[0044] In an exemplary aspect as shown in FIG. 2, the one or more carrier layers formed from the carrier composition can have a first carrier layer and a second carrier layer. In this aspect, the first carrier layer can define the uppermost surface of the carrier part. In a further aspect, the carrier part can optionally be one between the first and second carrier layers
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BE2017 / 5422 arranged glass fiber layer. Without wishing to be bound by any theory, the glass fiber layer can increase dimensional stability by reducing the possibility of shrinkage or growth after installation of the flooring product.
[0045] In various further aspects, the one or more carrier layers are formed from a carrier composition and have this. In one aspect, the first and second carrier layers have a carrier composition. In some embodiments, the first and second carrier layers can have the same carrier composition. In further aspects, the first and second carrier layers can have different carrier compositions.
[0046] In one aspect, the carrier composition comprises a polyolefin elastomer and a filler. In another aspect, the carrier composition may include, for example and without limitation, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), ethylene methacrylate (EMA), ethylene vinyl acetate (EVA), polyethylene polypropylene (PE-PP) rubber, conventional thermoplastic Elastomers (TPEs), conventional thermoplastic olefins (TPO), alpha-olefin-polyethylene copolymers, polyethylene terephthalate (PET), ethylene-butyl acrylate (EBA) and the like. In yet another aspect, the carrier composition comprises an ethylene-octene copolymer.
In another aspect, and as disclosed in U.S. Patent Application 11 / 963,263, which is incorporated herein by reference in its entirety, the carrier composition may include substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (ie, homogeneously branched ethylene polymers) that are low Solidification temperatures, good adhesion to polypropylene, and a low modulus compared to conventional ethylene polymers, such as low density polyethylene (LDPE), heterogeneously branched linear low density polyethylene (LLDPE), high density polyethylene (HDPE) and heterogeneously branched ultra-low density polyethylene Density (ULDPE). Exemplary support layers formed from the homogeneously branched ethylene polymers disclosed
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BE2017 / 5422 are shown in the figures as first or second carrier layers.
In a further aspect, the use of essentially linear ethylene polymers in the backing layer of the floor covering can allow the elimination of secondary backing materials and, as such, can lead to savings in manufacturing costs. In addition, flooring with a layer of essentially linear ethylene polymers or homogeneously branched linear ethylene polymers can provide an essential liquid and particle barrier that improves the hygienic properties of the flooring.
In another aspect, the homogeneously branched ethylene polymer of the carrier composition can be used alone or can be mixed or blended with one or more synthetic or natural polymer materials. Suitable polymers for blending or blending with homogeneously branched ethylene polymers used in the present invention include, but are not limited to, another homogeneously branched ethylene polymer, low density polyethylene, heterogeneously branched LLDPE, heterogeneously branched ULDPE, medium density polyethylene, high density polyethylene, Polyethylene grafts (for example a maleic anhydride extrusion-grafted heterogeneously branched linear low polyethylene or a maleic anhydride extrusion grafted homogeneously branched ultra-low density polyethylene), ethylene acrylic acid copolymer, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, polystyrene, polypropylene, polyester , Polyurethane, polybutylene, polyamide, polycarbonate, rubbers, ethylene-propylene polymers, ethylene-styrene polymers, styrene block copolymers and vulcanizates.
[0050] In one aspect, the polyolefin elastomer comprises a polyethylene elastomer. In another aspect, the polyolefin elastomer comprises a polypropylene elastomer. In yet another aspect, the polyolefin elastomer is a copolymer of propylene and ethylene. In yet another aspect, the propylene content of the copolymer is at least about 80%.
[0051] In one aspect, the carrier composition has from about 10 to about 50 based on the total weight of the carrier composition
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% By weight of polymer, including exemplary polymer parts by weight of 15% by weight, 20% by weight, 30% by weight, 35% by weight, 40% by weight, and 45% by weight. In yet another aspect, the carrier composition may include polymer in an amount ranging from any amount derived from the above values. For example, the polymer weight fraction can range from about 10% to about 40% by weight, or from about 15% to about 45% by weight.
In another aspect, the polymer may have from about 50 to about 100 weight percent polyolefin based on the total weight of the polymer, including example values of 55 weight percent, 60 weight percent, 65 weight percent, 70 weight percent, 71% by weight, 72% by weight, 73% by weight, 74% by weight, 75% by weight, 76% by weight, 77% by weight, 78% by weight, 79% by weight, 80% by weight , 85% by weight, 90% by weight, and 95% by weight. In still other aspects, the polymer can have polyolefin in a range derived from any two of the above exemplary weight percentages. For example, the polymer can have from about 51 to about 99 weight percent polyolefin, or from about 60 to about 90 weight percent polyolefin, based on the total weight of the polymer.
In various aspects, the exemplary polyolefin elastomer offers excellent physical properties including elasticity, toughness and low temperature ductility and high filler loading ability. In an exemplary aspect, the polyolefin elastomer is an ethylene-octene copolymer such as, but not limited to, ENGAGE ™ EG 8185 polyolefin elastomer (an ethylene-octene copolymer available from The Dow Company at a density of about 0.885 g / cm ³ ( ASTM D-792), a melt index of about 30 g / 10 min, determined according to ASTM D-1238 at 190 ° C and 2.16 kg, and a Mooney viscosity of about 33, determined according to ASTM D-1546 at ML 1 + 4 at 121 ° C), ENGAGE ™ EG 8100 polyolefin elastomer (an ethylene-octene copolymer available from The Dow Company at a density of about 0.870 g / cm ³ (ASTM D-792), a melt index of about 1.0 g / 10 min, determined according to ASTM D1238 at 190 ° C and 2.16 kg, and a Mooney viscosity of about 23,
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BE2017 / 5422 determined according to ASTM D-1546 at ML 1 + 4 at 121 ° C), AFFINITY ™ KC8852G polyolefin elastomer (an ethylene-octene copolymer available from The Dow Company with a density of about 0.875 g / cm ³ (ASTM D -792), and a melt index of about 3.0 g / min as determined according to ASTM D-1238 at 190 ° C and 2.16 kg).
In a further aspect, the carrier composition used to produce at least one of the carrier layers of the present invention has a filler. As will be appreciated by one skilled in the art, the type of filler used will be selected based on the desired physical properties of the final product. In yet another aspect, exemplary fillers can include, for example and without limitation, calcium carbonate, barium sulfate, heavy spar, glass fibers and powder, metal powder, aluminum oxide, hydrated aluminum oxide, clay, magnesium carbonate, calcium sulfate, silicon dioxide or glass, pyrogenic silica, talc, carbon black or graphite, Fly ash, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, wood flour, glass microspheres, chalk and mixtures thereof. In yet another aspect, additional fillers that can be used include graphite fiber, silica / glass, wollastonite, crushed glass, kaolin, mica, recycled fines, glass fiber, diatomaceous earth, lime, and mixtures thereof. In yet another aspect, an exemplary filler is fly ash, such as, and without limitation, Celceram ™ fly ash filler PV20A (a calcium aluminum silicate available from Boral). In a further aspect, the carrier composition can comprise post-industrial carpet and / or post-consumer carpet material. In yet another aspect, the carrier composition can comprise composite material made of post-industrial carpet and / or composite material made of post-consumer carpet. In some aspects, the glass filler is fine glass grains or broken glass. In other aspects, the fly ash is hard coal fly ash.
In a further aspect, the carrier composition may include a filler in an amount from about 65 to about 95% by weight, including exemplary filler weight percentages of 70% by weight, 71
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% By weight, 72% by weight, 73% by weight, 74% by weight, 75% by weight,
% By weight, 77% by weight, 78% by weight, 79% by weight, 80% by weight, 85% by weight, 90% by weight, and 94% by weight. In yet other aspects, the carrier composition may include a filler in an amount in a range derived from any two of the above exemplary weight percentages. For example, the carrier composition may have a filler in a range from about 70 to about 90% by weight, or from about 75 to about 85% by weight. In one aspect, the carrier composition has an 80% filled polyethylene composition. In another aspect, the carrier composition has an 80% filled ethylene-octene copolymer composition.
In a further aspect, the carrier composition of the present invention may optionally contain one or more additives, for example and without limitation, tacifiers, treatment agents, blowing agents, plasticizers or the like. In yet another aspect, the additive can include a hydrocarbon resin. In one aspect, the PICCOTAC ™ 1115 hydrocarbon resin, manufactured by Eastman Chemical and having a relatively high molecular weight, can be diene derived aliphatic C5 resin and other reactive olefin.
In a further aspect, the carrier composition may optionally comprise maleic anhydride grafts, wherein maleic anhydride is grafted onto an ethylene polymer in a concentration of from about 0.1 to about 5.0 percent by weight, preferably from about 1 to about 2 percent by weight. In yet another aspect, an exemplary composition for the formation of a maleic anhydride graft is the Amplify® GR 204 resin available from Dow Chemicals.
In a further aspect, the secondary carrier layer, if present, for example and without limitation, oriented polypropylene (OPP), woven polyethylene (PE), non-woven polyethylene (PE), woven polypropylene (PP), non-woven polypropylene (PP ), woven polyethylene terephthalate (PET), non-woven polyethylene terephthalate (PET), woven nylon, non-woven nylon and
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BE2017 / 5422 have the same. In yet another aspect, the secondary backing layer can be glass fiber nonwoven, glass fiber fabric, recycled fiber tear wool, polyethylene terephthalate (PET) film, polypropylene (PP) film, polyethylene (PE) film, linear low density polyethylene (LLDPE) film, polystyrene copolymer, Polypropylene-polyethylene (PP-PE) copolymer, polyolefin elastomer or polyurethane or a combination thereof. In yet another aspect, the secondary support layer has an embossed pattern.
In a further aspect, the glass fiber layer, if present, may have a glass fiber mat. In yet another aspect, the glass fiber layer can have a weight of about 20 to about 90 g / m ² , including exemplary values of about 30, 40, 50, 60, 70 or 80 g / m ² . In some aspects, the glass fiber mat can allow for increased binder polymer saturation and thus a reduction in the chance of delamination of highly filled first and second backing layers. In another aspect, a thinner glass fiber mat can more advantageously reduce the overall weight of the finished flooring product and is less expensive than thicker fiberglass. In other aspects, as shown in FIG. 7, the carrier layer formed from the carrier composition can also comprise fiberglass, for example chopped fiberglass. Thus, in one aspect, the resilient floor covering did not require a separate glass fiber layer.
Decorative part According to embodiments of the invention, the elastic
Flooring a decorative part. In one aspect, the decorative portion of the resilient floor covering may have a bottom surface and an opposite top surface. In a further aspect, the decorative part can have a color layer. In yet another aspect, the color layer can define the top surface of the decorative part. Optionally, the color layer can also define the lowest surface of the decorative part. In another aspect, the color layer can have a protective acrylic coating to aid processing and adhesion. In an additional aspect, the decorative part can be configured to overlie the support part. In this aspect, the decorative part in the
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Essentially adjoin the carrier part so that the top surface of the carrier part touches the bottom surface of the decorative part. It is contemplated that the paint layer can be applied either directly or indirectly to the top surface of the backing of the floor covering. Alternatively, the decorative part can be at a distance from the carrier part.
In a further aspect, the color layer can comprise any conventional ink, dye, pigment or other marking substance which can be applied in a desired pattern within the elastic floor covering. For example and without limitation, the color layer may include water-based, soy-based and / or solvent-based pigments that are selected to effectively adhere to the underlying decorative layer. In an exemplary aspect, the color layer may include inks and pigments made by Sun Chemical Corporation.
In another aspect, the color layer can be applied to the underlying decorative layer by any conventional printing device, which can include, without limitation, rotogravure printing, flexographic printing, lithographic printing, offset lithographic printing, relief printing, thermographic printing, thermal sublimation printing, dye sublimation printing, heat transfer printing and the like.
[0064] In a further aspect, the decorative part of the floor covering can have a decorative layer. In this aspect, the decorative layer can have any desired aesthetic appearance, such as, for example and without limitation, the appearance of imitation hardwood or ceramic floors. In one aspect, the decorative layer can define the bottom surface of the decorative part of the flooring. In another aspect, the color layer may be configured to overlie the decorative layer. In this aspect, the decorative layer can adjoin the color layer.
In a further aspect, the decorative layer can comprise a film. In yet another aspect, the decorative layer, for example and without limitation, oriented polypropylene (OPP),
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Polypropylene (PP) film, filled PP film, for example and without limitation, Teslin® substrate (commercially available from PPG Industries), polyethylene (PE) film, polyethylene terephthalate (PET) film, oriented polyethylene terephthalate (PET) film , Polytrimethylene terephthalate (PTT) film, nylon film, woven polyethylene (PE), non-woven polyethylene (PE), woven polypropylene (PP), non-woven polypropylene (PP), woven polyethylene terephthalate (PET), non-woven polyethylene terephthalate (PET) , woven nylon, non-woven nylon, nylon 6, nylon 6,6, conventional papers, conventional films, and the like. In yet another aspect, the decorative layer can include heat stabilized biaxially oriented PET (BOPET), amorphous PET (a-PET), recycled PET (rPET), glycol modified polyethylene terephthalate (PETG), polyolefin, cycloolefin copolymer (COC), cycloolefin polymer ( COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly (methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), polycarbonate, polyethylene (PE), or a copolymer thereof exhibit. In yet another aspect, the decorative layer can have a thickness in the range of about 1 mil to about 8 mils, including exemplary thicknesses of 2, 3, 4, 5, 6, or 7 mils.
In a further aspect, the decorative layer of the decorative part can comprise a three-layer film, e.g. and without limitation, a SynDECOR® OPP film manufactured by Applied Extrusion Technologies Inc. In this aspect, the three-layer film can have an uppermost skin, a central core and a lowermost skin. In one aspect, the uppermost skin can be configured to be compatible with the colored layer of the decorative part of the flooring. It is contemplated that at least a portion of the color layer can be applied to the top skin of the three layer film. In a further aspect, the central core of the three-layer film can have a solid material. In this aspect, the solid material can be substantially opaque. In this aspect, an opaque film can be used. Such an exemplary opaque film is desired because it creates a color barrier between the decorative layer and the subsequent carrier layers,
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BE2017 / 5422 which may differ in color can create. In another aspect, the bottom skin of the three-layer film can be configured to be compatible with the post-industrial carpet and / or post-consumer carpet materials that form part of the one or more main backing layers.
Wear layer In accordance with various aspects of the invention, the resilient floor covering has a wear layer. In another aspect, the wear layer may have an exposed outer surface and an opposite lowermost surface. In this aspect, the outer surface of the wear layer can be configured for exposure to the surrounding environment. In a further aspect, the wear layer can be configured such that it lies essentially over the decorative part of the floor covering. It is contemplated that the wear layer may adjoin the decorative part such that the top surface of the decorative part contacts the bottom surface of the wear layer. Alternatively, the wear layer can be spaced from the decorative part.
In one aspect, the wear layer may e.g. and without limitation, conventional ionomers, polyethylene terephthalate (PET), polyurethane, polypropylene, polytrimethylene terephthalate (PTT), nylon 6, nylon 6,6 and the like. In another aspect, the wear layer can be Surlyn resin such as and without limitation Surlyn® 1706 resin made by E.I. du Pont de Nemours and Company, Inc. In yet another aspect, the wear layer can include heat stabilized biaxially oriented PET (BOPET), amorphous PET (a-PET), recycled PET (rPET), glycol modified polyethylene terephthalate (PETG), polyolefin, cycloolefin copolymer (COC), cycloolefin polymer (COP ), Polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly (methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), polycarbonate, polyethylene (PE), high density polyethylene (HDPE ), Low density polyethylene (LDPE) or a copolymer thereof. In yet another aspect, the wear layer
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BE2017 / 5422 have a starch in the range of about 4 mils to about 30 mils, including exemplary starch ranges from about 4 to about 8 mils, about 9 to about 14 mils, or about 16 to about 30 mils. In yet another aspect, the strength may be in a range derived from any of the exemplary values listed above. For example, the strength can range from about 4 mil to about 9 mil, or from 4 mil to about 16 mil. In a further aspect, the wear layer can be embossed with a desired surface structure pattern.
[0070] In various aspects, the exposed outer surface portion of the wear layer may further include a scratch layer. In one aspect, the scratch layer comprises polyurethane or acrylate, or a combination thereof. In a further aspect, the scratch layer can have a mixture of reactive monomers and oligomers. In yet another aspect, the scratch layer can have functionalized monomers, for example and without limitation, difunctional and multifunctional monomers. In yet another aspect, the scratch layer may have at least one photoinitiator, or other component, to catalyze a reaction between the materials present in the scratch layer. In some aspects, the scratch layer has a mixture of epoxy acrylate oligomers with difunctional and multifunctional monomers.
In another aspect, the scratch layer has a surface hardener. In yet another aspect, the surface hardener aluminate, aluminum oxide, acrylic beads, silicon dioxide, glass balls, sol-gel aluminum oxide, nylon-orgasol, MF-silica optbeads, polyethylene dispersion, silyl-acrylic-set wet particles, wollastonite, clay, SilylAcryl-polysiloxane, sodium silicate, polyvinylidene difluoride (PVDF), silicon carbide, quartz or a combination thereof. In some aspects, the surface hardener is alumina, silica, or a combination thereof.
[0072] In another aspect, the scratch layer has a thickness in the range of about 0.25 to about 3 mils, including exemplary ranges of about
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0.50 to about 1.25 mils, and 0.50 to about 2.25 mils. In yet another aspect, the surface hardener is present in an amount ranging from about 0.25% by weight to about 15% % By weight, based on the total weight of the scratch layer, including exemplary ranges from about 2% by weight to about 3% by weight, and about 2% by weight to about 10% by weight, based on the total weight of the scratch layer. In some aspects, the surface hardener is present in an amount less than or equal to 10% by weight, for example less than about 9, 8, 7, 6, 5, 4, 3, 2 or 1% by weight, based on the total weight of the scratch layer. In another aspect, the surface hardener has particulate material that has an average particle size less than or equal to 20 microns, for example less than or equal to about 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 micrometers. In some aspects, the scratch layer adheres to an underlying wear layer part through a
Primer coating layer. In another aspect, the undercoat coating layer has a thickness in the range of about 0.25 to about 1 mil, for example from about 0.40 to about 0.6 mil.
Binding Layer According to various further aspects of the invention, the elastic floor covering can optionally have at least one binding layer. In one aspect, the at least one tie layer may be located between opposing layers of the resilient floor covering to bond otherwise dissimilar materials that form the otherwise opposing layers of the floor covering. Those skilled in the art will understand that such dissimilar materials can have inherent properties that adversely affect the ability of the corresponding materials to bond or otherwise adhere to one another.
In one aspect, one or more tie layers of the at least one tie layer may be located between the bottom surface of the wear layer and the top surface of the decorative part of the flooring. In a further aspect, a binding layer of the at least one binding layer can be between the lowest surface of the
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BE2017 / 5422 decorative part and the top surface of the support part.
In a further aspect, each of the at least one tie layer may include, for example and without limitation, polyethyleneimine (PEI), conventional acrylic materials, maleic anhydride (MAH), ethylene methyl acrylate (EMA), ethylene vinyl acetate (EVA), and the like, independently of one another. In yet another aspect, each of the at least one tie layer can include ethylene acrylic acid (EAA), ethylene acrylic acid maleic anhydride (EAA-MAH), ethylene methyl acrylate maleic anhydride (EMA-MAH), ethylene vinyl acetate maleic anhydride (EVA-MAH), low density polyethylene -Maleic anhydride (LDPE-MAH), high-density polyethylene-Maleic anhydride (HDPE-MAH), polyurethane (PUR), polyurethane dispersion (PUD), or acrylic independently.
In a further aspect, at least one binding layer can contain Entira ™ modifiers and additives such as, for example and without limitation, Entire ™ Coat 100 modifiers and additives, which can be obtained from E.I. du Pont de Nemours and Company, Inc. In yet another aspect, the at least one tie layer may include water-thinnable coating primers, including, for example and without limitation, G-680 primer manufactured by Mica Corporation. In yet another aspect, one or more of the opposing layers are pretreated with at least one of corona, plasma, ion flame, alcohol, ozone, UV, or primer coating before the one or more binding layers are positioned.
Leveling layer According to various further aspects of the invention, the elastic floor covering can optionally have at least one leveling layer. In one aspect, the at least one leveling layer can be positioned between opposing layers of the resilient flooring to provide support, for example for the support member. In a further aspect, the at least one leveling layer can be positioned on the lowermost surface of the flooring product.
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BE2017 / 5422 In a further aspect, the at least one leveling layer-oriented polypropylene (OPP), woven polyethylene (PE), non-woven polyethylene (PE), woven polypropylene (PP), non-woven polypropylene (PP), woven polyethylene terephthalate ( PET), non-woven polyethylene terephthalate (PET), woven nylon, non-woven nylon, glass fiber fleece, glass fiber fabric, recycled fiber tear wool or a combination thereof.
With reference now to the particular example shown in Figure 3, an exemplary construction of the flooring of the present invention is shown. In one aspect, the resilient floor covering, from above, has a wear layer that is bonded to either the top surface of the color layer of the decorative part or the top surface of the top binding layer, which may include, for example, ethylene acrylic acid maleic anhydride (EAAMAH). In a further aspect, a scratch layer forms the exposed outer part of the wear layer, which can have, for example, polyurethane and Al2O3. If necessary, a protective layer for the color layer may be present on the top surface of the color layer and under the top binding layer. Next comes connected to the bottom surface of the color layer, the film / decorative layer, which together form the decorative part. In one aspect, the film / decorative layer has two layers, a primer color layer and a protective lacquer layer. In a further aspect and as shown in the present exemplary embodiment, the protective lacquer layer can have one or more layers. In yet another aspect, the protective lacquer layer can have, for example, acrylic, the primer color layer can have, for example, PET film or film, and the color layer can have, for example, sun ink with Hartmann pigments. Next comes a first carrier layer which is connected to the lowermost surface of the film / decorative layer by means of a second binding layer and which, for example, can have an 80% filled polypropylene composition, such as Vertex 80. Alternatively, an optional smooth tie layer, which may have, for example, Affinity PE, can be bonded to the bottom surface of the second tie layer and the top surface of the first carrier layer film / decorative layer, if desired, or if the materials that the
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BE2017 / 5422 form adjacent layers that require the use of a smooth tie layer. Next comes a glass fiber layer connected to the lowermost surface of the first carrier layer and the uppermost surface of a second carrier layer, which together form the carrier part, for example a glass fiber mat. Finally, if desired, a friction layer, for example glue or felt, can be bonded to the lowermost surface of the second carrier layer.
Referring now to the particular example shown in Figure 4, another exemplary construction of the flooring of the present invention is shown. In one aspect, the resilient floor covering, from above, has a wear layer that is bonded to either the top surface of the color layer of the decorative part or the top surface of the top bond layer, which may include, for example, ethylene acrylic acid maleic anhydride (EAA-MAH). In a further aspect, a scratch layer forms the exposed outer part of the wear layer, which can have, for example, polyurethane and Al2O3. If necessary, a protective layer for the color layer may be present on the top surface of the color layer and under the top binding layer. Next comes connected to the bottom surface of the color layer, the film / decorative layer, which together form the decorative part. In one aspect, the film / decorative layer has two layers, a primer color layer and a protective primer lacquer layer. In a further aspect and as shown in the present exemplary embodiment, the protective lacquer layer can have one or more layers. In yet another aspect, the protective lacquer layer can have, for example, acrylic, the primer color layer can have, for example, PET film or film, and the color layer can have, for example, sun ink with Hartmann pigments. Next comes a first carrier layer which is connected to the lowermost surface of the film / decorative layer by means of a second binding layer and which, for example, can have an 80% filled polypropylene composition, such as Vertex 80. Alternatively, an optional smooth binding layer, which may have Affinity PE, for example, with the lowermost surface of the second binding layer and the
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BE2017 / 5422 top surface of the first carrier layer can be connected to the film / decorative layer, if this is desired, or if the materials which form the adjacent layers require the use of a smooth binding layer. Finally, if desired, a friction layer, for example glue or felt, can be bonded to the lowermost surface of the second carrier layer.
Properties of the Resilient Flooring According to various aspects of the disclosure, the resilient flooring of the present invention exhibits improved physical and mechanical properties.
In one aspect, the wear layer exhibits an abrasion resistance greater than 5000 cycles when measured according to ASTM D3884 under test conditions that have cleaned an H18 wheel, 1000 grams load, and every 300 cycles, including exemplary abrasion resistance greater than 5000 Cycles, more than 10,000 cycles, or more than 20,000 cycles when measured according to ASTM D3884 under test conditions that have an H18 wheel, 1000 gram load, and cleaned every 300 cycles.
In one aspect, the scratch layer, in combination with the wear layer, shows an abrasion resistance greater than 5000 cycles when measured according to ASTM D3884 under test conditions that clean an H18 wheel, 1000 grams load, and every 300 cycles, including exemplary Abrasion resistance greater than 5000 cycles, more than 10,000 cycles, or more than 20,000 cycles when measured according to ASTM D3884 under test conditions that include an H18 wheel, 1000 gram load, and cleaned every 300 cycles.
In one aspect, the scratch layer exhibits abrasion resistance in a range of about 100 cycles to 500 cycles when measured according to ASTM D3884 under test conditions including an H18 wheel, 1000 gram load, and cleaned every 300 cycles, including exemplary Abrasion resistance ranges from about 100 cycles to 400 cycles, or from about 200 cycles to 300 cycles when measured according to ASTM D3884 under test conditions involving an H18 wheel, 1000 grams of load, and every 300 cycles
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BE2017 / 5422 cleaned.
In one aspect, the exposed outer surface of the wear layer shows a micro-scratch resistance, which is characterized by a gloss change value in the range from 1 to 3, measured according to Martindale test EN 16094-2012 test A (MSR-A) or test B (MSR -B) by visual assessment of surface scratching.
In one aspect, the scratch layer exhibits a heat stability of less than about 12 average delta E's as determined by ASTM F1514 or ASTM F1515, for example less than about 8 average delta E's as determined by ASTM F1514 or ASTM F1515 ,
[0090] In one aspect, the scratch layer shows a coating adhesion value in the range from 4B to 5B, measured according to ASTM-D3359-02 type B. In a further aspect, the scratch layer shows a degree of gloss in the range from 5 to 50, as with a BYK Gardner Micro-Gloss 60 degree instrument measured. In yet another aspect, the scratch layer exhibits a gloss level in the range of 6 to 30 as measured with a BYK Gardner Micro-Gloss 60 degree instrument.
In a further aspect, the scratch layer shows a micro-scratch resistance, which is characterized by a change in gloss value in the range from 1 to 3, measured according to Martindale test EN 16094-2012 test A (MSR-A). In yet another aspect, the scratch layer shows a micro-scratch resistance which is characterized by a change in gloss value in the range from 1 to 3, measured according to Martindale test EN 16094-2012 test B (MSR-B).
In one aspect, the disclosed resilient floor coverings exhibit static load limit indentation behavior in the range from about 0 inches to about 0.09 inches as measured according to ASTM F970 under the conditions: 24 hours 250 lbs. static load, 24 hour recovery, and 1.125 inch outer diameter probe, including exemplary static load limit indentation ranges from about 0 inches to about 0.07 inches, or from about 0 inches to about 0.05 inches, as per ASTM F970 below the conditions measured: 24 hours 250 Ib. static load, 24 hour recovery, and 1.125 inch outer diameter probe.
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BE2017 / 5422 In one aspect, the resilient flooring disclosed shows short term residual impression behavior in the range of 0 inches to 0.09 inches measured according to ASTM F1914 under the conditions: 10 minute load with 140 lb., 60 minute recovery; including exemplary short term residual impression behavior ranges from about 0 inches to about 0.07 inches, or from about 0 inches to about 0.05 inches, as measured according to ASTM F1914 under the conditions of: 10 minutes of exposure to 140 lb., 60 minutes of recovery.
In one aspect, the disclosed resilient floor coverings show a critical radiation flow of a class 2 flame spread as measured according to ASTM-E648. In another aspect, the disclosed resilient floor coverings can show a critical radiation flow of a class 1 flame spread as measured according to ASTM-E648.
[0095] In one aspect, the resilient floorings disclosed exhibit dimensional stability less than about 0.17% as determined by ASTM F21990 at 82 ° C and 24 hours, including dimensional stability values less than about 0.15% or less than about 0, 10% as determined by ASTM F2199-0 at 82 ° C and 24 hours. In another aspect, the resilient floor coverings disclosed can exhibit dimensional stability characterized by an amount of doming or frizz ranging from 0 to no more than 3/32 of an inch when ASTM F2199-0 test conditions at 82 ° C and 24 Subject to hours. In yet another aspect, dimensional stability is characterized by an amount of doming or crimp of less than about 3/32 of an inch when subjected to ASTM F2199-0 test conditions at 82 ° C and 24 hours, for example less than about 1/16 of an Inches when subjected to test conditions of ASTM F2199-0 at 82 ° C and 24 h.
Methods of Manufacturing In various aspects, methods of manufacturing the resilient flooring are also disclosed. In one aspect, a method of making the resilient flooring described herein may include providing the support member as described herein. Alternatively, in a further aspect, the process for producing the
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BE2017 / 5422 resilient flooring described herein comprise the decorative part being applied to the top surface of the support member. In a further aspect, the method for producing the resilient floor covering, which is described herein, can comprise that a binding layer as described here is applied to the top surface of the carrier part. In this aspect, the method of making the resilient floor covering described herein may include applying the decorative portion to the tie layer that is applied to the carrier portion. It is contemplated that the lowermost surface of the decorative member may be applied substantially directly to the uppermost surface of the carrier member or to the bonding layer applied to the carrier member. It is also contemplated that the bottom surface of the decorative member may be applied to the top surface of the carrier member or to the bonding layer applied to the carrier member using a chemical adhesive, mechanical bond, or other application means.
Optionally, the method described herein for making resilient floor coverings may include in an additional aspect that the wear layer is applied to the top surface of the decorative part. In an alternative aspect, the method for manufacturing resilient floor coverings described herein may include applying one or more bonding layers described herein to the top surface of the decorative part. In this aspect, the method for manufacturing resilient floor coverings described herein may include applying the wear layer to the bonding layer applied to the decorative part. It is contemplated that the wear layer may be applied substantially directly to the top surface of the decorative part or to the tie layer applied to the decorative part. It is also contemplated that the wear layer may be applied to the top surface of the decorative part or to the bonding layer applied to the decorative part using a chemical adhesive, mechanical bond, or other application means. In another aspect, the wear layer that
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BE2017 / 5422 has an exposed outer surface part, applied to an uppermost surface of the decorative part, and the exposed outer surface part of the wear layer further has a scratch layer.
[0099] In various aspects, the chemical adhesive can include any adhesive. In a further aspect, the chemical adhesive can contain at least one of ethylene-acrylic acid-maleic anhydride (EAAMAH), ethylene-methyl acrylate-maleic anhydride (EMA-MAH), ethylene-vinyl acetate (EVA), ethylene-acrylic acid-maleic anhydride (MAH-EAA), ethylene-methyl acrylate (EMA), ethylene vinyl acetate (EVA), polyurethane (PUR), polyurethane dispersion (PUD) or acrylic adhesive. In yet another aspect, the adhesive can include a film or powder. In yet another aspect, the adhesive is heat activated, UV hardened or eBeam hardened. In some aspects, the adhesive is EAA-MAH.
In various aspects, the disclosed layers of the resilient flooring can be designed or otherwise formed by conventional methods and / or processes. Similarly, it is contemplated that the corresponding layers can be joined together in sequential or non-sequential order. Unless otherwise specified, no particular order of product formation steps is required to practice the present invention. It is also contemplated that any conventional means of forming or joining layers of a layered construction such as the illustrated resilient floor covering may be used, including without limitation extrusion, lamination, combinations thereof, and the like. Finally, it is contemplated that after the layers of the floor covering have been bonded together, the resulting web of floor covering composite can be cut to the desired shape and size, for example and without limitation, in plank or tile form which are conventional or non-conventional sizes and can have shapes.
[00101] In one aspect, as disclosed herein, the materials selected for the corresponding layers of flooring can be easily
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BE2017 / 5422 can be recycled. It is contemplated that one or more of the corresponding layers may include recycled post-consumer and / or post-industrial carpet, such as and without limitation, recycled post-consumer and / or post-industrial carpet polymer materials. In this regard, the molded flooring can minimize the use of brand new materials and advantageously allow the use of already recycled materials to form the recyclable flooring of the present invention.
[00102] In one aspect, an exemplary method of making the resilient flooring may initially include the step of adhering the one or more layers of paint to the top surface of the film / decorative layer using conventional means. Thereafter, a tie layer can subsequently be applied to the uppermost surface of the paint layers, if desired or if the materials which form the corresponding paint layers and wear layer require the use of a tie layer. Optionally, the tie layer can be extruded or laminated to the top surface of the color layer. In some aspects, the film / decorative layer has the three-layer AET SynDECOR® OPP film and the color layer has Sun Ink with Hartmann pigments. In this particular example, two successive binding layers are applied, Mica G680, which touches the top surface of the color layer, and Entira ™ Coat 100, which is applied to the top surface of the Mica G680 binding layer.
In a further aspect, a first carrier layer is extruded or otherwise connected to the lower surface of the films / decorative layer, and a glass fiber mat layer is embedded in the lower surface of the first carrier layer. Of course, if necessary, an optional binding layer can be connected to the bottom surface of the film / decorative layer before this step.
In another aspect, a wear layer is extruded or otherwise bonded to either the top surface of the paint layer or the top surface of the top tie layer. It is being considered
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BE2017 / 5422 drawn that, if required, the application of the binding layer on the top surface of the color layer and the application of the wear layer on the top binding layer of the color layer can be carried out in succession in a coextrusion process. In some aspects, the Entira ™ Coat 100 tie layer and the Surlyn® 1706 wear layer can be applied sequentially to the top surface of the underlying Mica G680 tie layer.
In a further aspect, a second carrier layer can be extruded thereon or otherwise connected to the lowermost surface of the glass fiber mat layer in order to completely encapsulate the glass fiber layer. In one example, referring to FIG. 2, the corresponding first and second carrier layers can have the carrier composition described herein. Thereafter, if desired, a secondary carrier, such as the illustrated nonwoven polypropylene secondary carrier, can be extruded thereon or otherwise bonded to the bottom surface of the second carrier layers.
Of course, as mentioned in Figure 2, an optional binding layer could be applied to the bottom surface of the film / decorative layer, if desired or if the materials forming the film / decorative layer and the first carrier layer were otherwise incapable are to connect effectively with each other. In some aspects, a tie layer may be unnecessary to provide the desired bond between the three-layer AET SynDECOR® OPP film (the film / decorative layer) and the first backing layer. In some aspects, as shown in Figures 3 and 4, a scratch layer can form the exposed outer surface portion of the wear layer.
[00107] In one aspect, the color layer is initially applied to the top surface of the decorative layer. The first carrier layer is then applied to the lowermost surface of the decorative layer, and the glass fiber material layer is applied to the lowermost surface of the first carrier layer. After that, the tie layer is on the color layer and the wear layer is on the top surface of the tie layer
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BE2017 / 5422 applied. Finally, the second carrier layer is subsequently applied to the glass fiber material layer, as a result of which the secondary carrier layer adheres to the lowermost surface of the glass fiber material layer.
In another aspect, each layer or part of the resilient flooring can be made by traditional manufacturing processes or laminated together, such as, but not limited to, a static press. As would be appreciated by one of ordinary skill in the art, the method used for lamination in a static press would involve the use of heat and pressure between the metal plates for a period of time to compress each of the desired layers described herein. For example and without limitation, a combination of the wear layer, tie layer (s), coloring, film / decorative layer, tie layer (s) and one or more backing layers would be stacked in the desired order and placed in the static press laminated together with the aforementioned combination of heat and pressure. In yet another aspect, one or more of the metal plates used to compress the layers or portions of the resilient floor covering may include an embossed texture to transfer them to the top or bottom surface of the resilient floor covering. In yet another aspect, this embossed texture could include a design desired for the wear layer that is inherent in the end product.
In a further aspect, the binding layer can be added before the lamination of the film / decorative layer and / or the wear layer by extrusion coating. As would be appreciated by one skilled in the art, a typical film extrusion process is used in which the tie layer is melted and poured through a slot die to apply a desired amount of the material to the film. After coating the film with the extrusion process, the material is quenched or adjusted using a typical cooling process, such as chill rolls, before the coated film is rolled again. In yet another aspect, the tie layer may be in the form of a liquid hot melt or cold melt adhesive and may be spray or
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Roll coating processes of the film / decorative layer and / or the wear layer can be added. In yet another aspect, and as would be recognized by one of ordinary skill in the art, the bonding layer is applied to the film in liquid form by spraying or roller coating devices, and then dried by heat, air or other curing agents before the film is re-rolled.
In some aspects, each individual layer or part of the resilient flooring can be made independently prior to making the resilient flooring. For example, and now referring to the particular example shown in Figure 5, is an example system for
Production of the carrier layer shown. Here, the
A carrier composition, which may optionally have a tacifier, recycling material, and / or crushed glass fibers, compounded, extruded and rolled through a calender to form the carrier layer. The backing layer formed is then wound up into rolls by the core winder which can later be used to produce the resilient floor coverings disclosed.
In other aspects, each layer or part of the resilient flooring can be made inline with the manufacture of the resilient flooring. For example, and now referring to the particular example shown in Figure 6, an exemplary system for making the resilient flooring is shown that uses inline compounding and melt extrusion of the carrier composition. In another aspect, a release layer 619, such as a release spray or film, direct contact felt applicator, or optionally release paper, is dispersed onto an upper surface of a cooled, moving lower conveyor belt 626. Further, if necessary, a secondary backing 607 is rolled onto the release liner 619, followed by, if the secondary backing 607 is used, a binder layer 602 is extruded onto an upper surface of the secondary backing 607. Subsequently, the carrier composition 620, which has resin binder 614 and filler 615, which may optionally have a tacifier 616, recycling material 617, and / or shredded glass fibers 618, is compounded inline and onto which
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Binding layer 602 applied. In the embodiment in which the carrier layer of the carrier part has a first carrier layer 604a and a second carrier layer 604b, a glass fiber mat layer 606 can be rolled onto the first carrier layer 604a, and subsequently the carrier composition 620 is compounded inline and applied to the glass fiber mat layer 606. In this embodiment, the second carrier layer 604b defines the lowermost surface of the carrier part and the first carrier layer 604a defines the uppermost surface of the carrier part. Here, if a secondary carrier layer 607 is used, it is contemplated that the first carrier layer 604a and the second carrier layer 604b are configured to substantially overlie the secondary carrier layer 607.
In a further aspect, a tie layer 602 may then be placed on the top surface of the exposed carrier composition forming the carrier portion, and optionally may be operatively laminated using an infrared heater 621. In yet another aspect, a printed film layer 603, for example polyethylene terephthalate (PET) or oriented polypropylene (OPP), is placed on the binding layer 602, and an additional binding layer 602 is applied to the top surface of the printed film layer 603, which in turn, if necessary, by means of of an infrared heater 621 can be functionally laminated. In a next step, a wear layer 601, for example amorphous polyethylene terephthalate (a-PET), or Surlyn, or OPP, is applied, and subsequently the release layer 619 is separated before the flooring product is passed through a press zone 622, for example through an isobaric press quench zone formed by the cooled moving lower conveyor belt, and a cooled opposite moving upper conveyor belt. Next, the flooring product is optionally passed through a pair of opposed heated rollers to emboss 623 the flooring product as desired before the flooring product is cut 624 into a desired size and / or shape and stacked 625.
In a further aspect and now referring to the specific example shown in FIG. 7, an exemplary system is
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Manufacture of flooring shown. In another aspect, a separation layer 719, such as a separation spray or film, or direct contact felt, or optionally a release paper, is dispersed onto a top surface of a heated and cooled moving lower conveyor belt 726. Furthermore, a secondary carrier layer 707 is optionally rolled onto the separating layer 719, followed by the fact that, if the secondary carrier layer 707 is used, a binding layer 702 is extruded onto an uppermost surface of the secondary carrier layer 707. Subsequently, the carrier composition 720, which has resin binder 714 and filler 715, which can optionally have a tacifier 716, recycling material 717, and / or shredded glass fibers 718, is compounded inline and applied to the binding layer 702. In embodiments in which the carrier layer of the carrier part has a first carrier layer 704a and a second carrier layer 704b, a glass fiber mat layer 706 can be rolled onto the first carrier layer 704a, and subsequently the
Carrier composition 720 compounded inline and on the
Glass fiber mat layer 706 applied. In this embodiment, the second carrier layer 704b defines the lowermost surface of the carrier part and the first carrier layer 704a defines the uppermost surface of the carrier part. Here, if a secondary carrier layer 707 is used, it is contemplated that the first carrier layer 704a and the second carrier layer 704b are configured to substantially overlie the secondary carrier layer 707.
In a further aspect, a binding layer 702 can then be arranged on the uppermost surface of the exposed carrier composition forming the carrier part, and optionally functionally dried by means of an infrared heater 721. A printed film layer 703, for example polyethylene terephthalate (PET) or oriented polypropylene (OPP), is arranged on the binding layer 702, and an additional binding layer 702 is applied to the uppermost surface of the printed film layer 703, which in turn is optionally functionally laminated by means of an infrared heater 721 can be. In a next step, a wear layer 701, for example amorphous polyethylene terephthalate (a-PET), or Surlyn, or OPP, is applied, and
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BE2017 / 5422 subsequently the separation layer 719 is separated before the flooring product is passed through a press zone 722, for example an isobaric press quench zone formed by the heated and cooled moving lower conveyor belt and a heated and cooled opposite moving upper conveyor belt , In this aspect, it is contemplated that the isobaric quench zone sequentially heats and then cools the flooring product as it passes through this quench zone. Next, the flooring product is optionally passed through a pair of opposed heated rollers to emboss 723 the flooring product as desired before the flooring product is cut 724 into a desired size and / or shape and stacked 725.
In a further aspect and now referring to the specific example shown in FIG. 8, an exemplary system for producing the floor covering is shown. In another aspect, a separation layer 819, such as a separation spray or film, or direct contact felt, or optionally a release paper, is dispersed on an uppermost surface of a moving lower conveyor belt 826. Further, if necessary, a secondary support layer 807 is rolled onto the separation layer 819, followed by, if the secondary support layer 807 is used, a binding layer 802 is extruded onto an uppermost surface of the secondary support layer 807. The carrier composition is then applied to the binding layer. As shown, it is contemplated that the carrier composition may be formed in a film state that may subsequently be applied in layers to form a first carrier layer 804a. In a further aspect, a glass fiber mat layer 806 can subsequently be rolled onto the first carrier layer 804a, and subsequently the carrier composition, in the form of film layers, can be applied onto the glass fiber mat layer 806. In this embodiment, the second carrier layer 804b of the at least one carrier layer defines the lowermost surface of the carrier part and the first carrier layer 804a of the at least one carrier layer defines the uppermost surface of the carrier part. Here is if a secondary backing
2017/5422
BE2017 / 5422
807 is used, it is contemplated that the first carrier layer 804a and the second carrier layer 804b are configured to substantially overlie the secondary carrier layer 807.
Subsequently, a binding layer 802 can then be arranged on the uppermost surface of the exposed carrier composition forming the carrier part, and optionally functionally dried by means of an infrared heater 821. A printed film layer 803, for example polyethylene terephthalate (PET), or oriented polypropylene (OPP) is arranged on the binding layer 802, and an additional binding layer 802 is applied to the uppermost surface of the printed film layer 803, which in turn is optionally functionally laminated by means of an infrared heater 821 can be. In a next step, a wear layer 801, for example amorphous polyethylene terephthalate (aPET), or Surlyn, or OPP, is applied, and subsequently the separating layer 819 is separated before the flooring product is passed through a press zone 822, for example through an isobaric press quench zone, which is formed by the heated and cooled moving lower conveyor belt, and a heated and cooled opposite moving upper conveyor belt. In this aspect, it is contemplated that the isobaric quench zone sequentially heats and then cools the flooring product as it passes through this quench zone. Next, the flooring product is optionally passed through a pair of opposed heated rollers to emboss 823 the flooring product as desired before the flooring product is cut 824 into a desired size and / or shape and stacked 825.
In a further aspect and now referring to the specific example shown in FIG. 9, an exemplary system for producing the floor covering is shown. In another aspect, a separation layer 919, such as a separation spray or film, or direct contact felt, or optionally a release paper, is dispersed onto a top surface of a heated and cooled moving lower conveyor belt 926. Furthermore, if necessary, a secondary carrier layer 907 is applied to the
2017/5422
BE2017 / 5422
Release layer 919 is unrolled, followed by the fact that if secondary backing 907 is used, a tie layer 902 is extruded onto a top surface of secondary backing 907. Subsequently, the carrier composition, which is in pellet form, is applied to the bonding layer 902 and optionally preheated with, for example and without limitation, a conventional infrared preheater 927 or the like. In one embodiment, in which the carrier layer of the carrier part has a first carrier layer 904a and a second carrier layer 904b, a glass fiber mat layer 906, or optionally crushed glass fibers 918, and / or filler 915 can be applied to the first carrier layer 904a, and subsequently the carrier composition 920, which is in pellet form, is applied to the glass fiber mat layer 706 and optionally preheated with, for example and without limitation, a conventional infrared preheater 927 or the like. In this embodiment, the second carrier layer 904b of the at least one carrier layer defines the lowermost surface of the carrier part and the first carrier layer 904a of the at least one carrier layer defines the uppermost surface of the carrier part. Here, if a secondary carrier layer 907 is used, it is contemplated that the first carrier layer 904a and the second carrier layer 904b are configured to substantially overlie the secondary carrier layer 907.
Subsequently, a binding layer 902 can then be arranged on the uppermost surface of the exposed carrier composition forming the carrier part, and optionally functionally dried by means of an infrared heater 921. In a further aspect, a printed film layer 903, for example polyethylene terephthalate (PET), or oriented polypropylene (OPP), is arranged on the binding layer 902, and an additional binding layer 902 is applied to the uppermost surface of the printed film layer 903, which in turn, if necessary, by means of a Infrared heaters 921 can be dried properly. In a next step, a wear layer 901, for example amorphous polyethylene terephthalate (a-PET), or Surlyn, or OPP, is applied, and subsequently the separating layer 919 is separated off before the
2017/5422
BE2017 / 5422
Flooring product is passed through a press zone 922, for example through an isobaric press quench zone formed by the heated and cooled moving lower conveyor belt and a heated and cooled opposite moving upper conveyor belt. In this aspect, it is contemplated that the isobaric quench zone sequentially heats and then cools the flooring product as it passes through this quench zone. Next, the flooring product may be passed through a pair of opposed heated rollers to emboss the flooring product 923 as desired before the flooring product is cut 924 into a desired size and / or shape and stacked 925.
In a further aspect and now referring to the specific example shown in FIG. 10, an exemplary system for producing the floor covering is shown. In a further aspect, the elastic floor covering can be produced by a press roll method, for example by applying the layers of rolls using a winder. The carrier layer formed is rolled onto an uppermost surface of a press roll. If necessary, a secondary carrier layer can first be rolled onto the conveyor belt, and then subsequently when the secondary carrier layer is used. In the embodiments in which the carrier layer of the carrier part has a first carrier layer and a second carrier layer, a glass fiber mat layer can be rolled onto the first carrier layer and, subsequently, the second carrier layer can be rolled onto the glass fiber mat layer. In this embodiment, the secondary carrier layer defines the lowermost surface of the carrier part and the first carrier layer defines the uppermost surface of the carrier part. Here, if a secondary backing layer is used, it is contemplated that the first backing layer and the second backing layer are configured to substantially overlie the secondary backing layer.
In a next step, a wear / image layer is unrolled and applied to the flooring product and the flooring product is optionally passed between a pair of opposing rollers to emboss the flooring product as desired before
2017/5422
BE2017 / 5422 cut the flooring product into a desired size and / or shape, and stack it. In a further aspect, each rolled layer can optionally be functionally heated using an infrared heater or dryer.
In one aspect, the resilient flooring can be installed either using adhesive to adhere to a sub-floor or floating with an edge connection. In another aspect, and now with reference to the particular example shown in Figure 11, the resilient flooring product is subjected to an edge trimming or profiling step to, for example and without limitation, form an edge connection by saw, punch, or ultrasound. In a next step, a scratch layer is applied by roller coater and the flooring product is then passed through a hot air dryer zone and an infrared or e-beam zone prior to packaging.
In a further aspect, the edge profile can have any desired edge profile design, for example and without limitation, a click lock or tongue and groove connection system. In some aspects, the edge profile for joining can have a more complex geometry. In another aspect, the edge connection system can substantially restrict side-to-side and vertical movement. In yet another aspect, the connection seams, once installed, are all uniform and flat at each connection point. In yet another aspect, the edge profile can be different for all four edges.
In a further aspect, the edge profile can be formed by any means, for example by drilling, milling or profiling process or the like. In yet another aspect, the construction of the vinyl-free product must be developed to enable the drilling, milling, or profiling process to introduce the correct edge profile design.
[00124] As one skilled in the art will recognize, the carrier composition formulation, in various aspects, can affect the stability of the carrier part, for example the relative amounts and types of filler and polyolefin elastomer used in the formulation.
2017/5422
BE2017 / 5422
In another aspect, additives such as tackifiers, blowing agents, processing aids and plasticizers can also affect the stability of the formulation. In yet another aspect, an unstable support member can have weak edge connection profiles that can be easily damaged. In yet another aspect, the smoothness and uniformity of the edge connection profile can be affected by the carrier composition formulation. In yet another aspect, the wear layer and the scratch layer can delaminate, melt, or flake off during the edge profiling process or while the flooring is being installed.
[00125] In various aspects, the resilient floor coverings of the present invention advantageously exhibit no chipping, melting, or delamination during the edge profiling process. In a further aspect, the disclosed elastic floor coverings do not show any brittle or weak edge connection profiles.
EXAMPLES The following examples are provided to provide those skilled in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and / or methods claimed herein are made and evaluated, and are intended to be exemplary only be and not limit the revelation. Efforts have been made to ensure accuracy in terms of numbers (e.g. quantities, temperature, etc.), but some errors and deviations should be taken into account.
Example 1:
[00129] In this example, carrier layers according to the present invention are made using the exemplary carrier composition formulations provided in Tables 1 and 2.
Table 1.
Example A
Example B
Example C
Example D
Example E
KomponentenGew.%
Wt.%
Wt.%
Wt.%
% By weight description
2017/5422
BE2017 / 5422
Example A Example B Example C Example D Example E component Description Wt.% Wt.% Wt.% Wt.% Wt.% BoralFlugaschenfüllstoffPV20A 80.0% 80.0% 78.0% 80.0% 80.0% CaCO3 filler 0.0% 0.0% 0.0% 0.0% 0.0% ENGAGE ™ EG8185resin 20.0% 15.0% 20.0% 10.0% 5.0% Dow AMPLIFY ™GR204 resin 0.0% 0.0% 0.0% 5.0% 10.0% PICCOTAC ™ 1115Tacifier 0.0% 5.0% 0.0% 5.0% 5.0% Amorphous silicate 0.0% 0.0% 0.0% 0.0% 0.0% Crushed glass fibers 0.0% 0.0% 2.0% 0.0% 0.0%
Table 2.
Example G Example H Example J Example K component Description Wt.% Wt.% Wt.% Wt.% Boral fly ash fillerPV20A 0.0% 0.0% 0.0% 87.0% CaCO3 filler 80.0% 80.0% 74.0% 0.0% ENGAGE ™ EG8185 resin 20.0% 15.0% 19.0% 13.0% Dow Amplify GR204 resin 0.0% 0.0% 0.0% 0.0% PICCOTAC ™ 1115 Tacifier 0.0% 0.0% 5.0% 5.0% Amorphous silicate 0.0% 0.0% 2.0% 0.0%
2017/5422
BE2017 / 5422
Example G Example H Example J Example K component Description Wt.% Wt.% Wt.% Wt.% Crushed glass fibers 0.0% 0.0% 0.0% 0.0%
As shown above, the carrier compositions can be highly filled, from about 74 to about 87% by weight filler, for example, fly ash, calcium carbonate and / or amorphous silicate.
Example 2:
In this example, from the exemplary
Carrier compositions Carrier layers using isobaric
Double conveyor belt presses formed by two manufacturers: HELD Technologie GmbH (HD manufacturing process) and Hymmen Industrieanlagen GmbH (HN manufacturing process) under different temperatures and pressures.
The materials are then tested for dimensional stability in accordance with ASTM F2199. Dimensional stability and density results are provided in Tables 3 and 4 below.
Table 3.
product features resizing dimension production methodHD Immediate change [%] 24 h change [%] Thickness [mm] Density [g / cc] Example A 0.03% 0.08% 2.69 1.85 Example D -0.19% -0.07% 2.40 1.80 Example E -0.24% -0.27% 2.71 2.03 Example G -0.11% -0.09% 3.01 1.82 Example H 0.00% 0.00% 2.34 1.81 Example J -0.01% -0.03% 2.7 1.61
Table 4.
product features
resizing
dimension
2017/5422
BE2017 / 5422
production methodHN Immediate change [%] 24 h change [%] Thickness [mm] Density [g / cc] Example A 0.00% 0.00% 2.82 1.84 Example B -0.02% 0.00% 2.95 1.96 Example D roles -0.23% -0.13% 2.82 1.81 Example D pellet -0.13% -0.03% 2.18 1.97 Example G low pressure 0.41% 0.36% 2.76 1.86 Example G high pressure 0.07% 0.06% 2.84 1.84 Example H 0.11% 0.07% 2.43 1.77
As the results show, Examples A, G, H and J, which were produced by means of the HD process, are advantageously dimensionally stable below the limit of <0.017%. Examples A, B D, G, H, which were produced by means of the HN process, are also advantageously dimensionally stable below the limit of <0.017%.
Example 3:
In this example, abrasion resistance of exemplary film compositions that can be used to form the wear layer are assessed according to ASTM D3884 under test conditions 10 that have an H18 wheel, 1000 gram load, and cleaned every 300 cycles. The film composition parameters and their Taber wear test data are provided in Table 5 below.
Table 5.
film Sample Starch [mil] Gauge Polymer type Taber Test 1 [cycles] Taber Test 2 [cycles] Sample 1 7 700 PC 11400 > 20000 Sample 2 15 1500 PC - > 20000 Sample 3 7 700 PC 5000 11028
2017/5422
BE2017 / 5422
film Sample Starch [mil] Gauge Polymer type Taber Test 1 [cycles] Taber Test 2 [cycles] Sample 4 7 700 PC 10000 12300 Sample 5 12 1200 Polyester TPU > 16000 - Sample 6 15 1500 Polyester TPU - > 20000 Sample 7 15 1500 Polyester TPU - > 20000 Sample 8 15 1500 PET - 15000 Sample 9 10 1000 PET - 8500 Sample 10 15 1500 AP ET > 25000 - Sample 11 20 2000 AP ET - > 20000 Sample 12 10 1000 PET > 16000 > 20000 Sample 13 7.5 750 PET 19700 > 20000 Sample 14 6.34 634 PET 11500 > 20000 Sample 15 10 1000 AP ET > 20000 > 20000 Sample 16 15 1500 PETG / PET / PETG - > 20000 Sample 17 10 1000 PET - > 20000 Sample 18 15 1500 PC - > 20000 Sample 19 14 1400 PET > 20000 - Sample 20 7.87 787 Cellulose acetate 3425 5416 Sample 21 11.8 1180 Cellulose acetate 11000 10750 Sample 22 15.75 1575 PC 14705 14400 Sample 23 3 300 PP 897 - Sample 24 4 400 COC 1350 - Sample 25 5 500 HS BOPET 17700 -
2017/5422
BE2017 / 5422 [00136] Example 4:
In this example, resilient flooring samples having a scratch layer are made using the methods described herein and tested for scratch and abrasion performance. The backing layer was formed from the backing composition described in Example 1, Example D, and the scratch layer was formed from Nicoat U295365 polyurethane coating. The samples were tested for micro scratch resistance according to Martindale test EN 16094-2012 Test A (MSR-A) and Test B (MSR-B), and Shaw Scheuer test. The Shaw Scheuer test is a modified Crock10 test method for determining the abrasion resistance, which compares visual traces of abrasion from hard surfaces by means of a sanding pad for a certain number of cycles. The scrub and scratch test results are provided in Tables 6 and 7 below.
Table 6.
M artindale (A £ <B): Test method A (gloss level) Sample ID Ri Rf Delta R MSR-A Rtg grade C 17.2 13.9 19% 2 passed D 18.8 13.8 27% 2 passed e 18.2 13.8 24% 2 passed
Table 7.
Test procedure B visually) S haw scouring Sample ID MSR-B Rtg grade Sample ID rating grade 4 2 passed C 400 passed 5 3 passed ... ... ...
2017/5422
BE2017 / 5422
6 4 failed ... ... ...
[00138] As the results show, the scratch layer was able to achieve good resistance to scratch and abrasion tests.
[00139] Although several embodiments of the invention have been disclosed in the foregoing description, it will be apparent to those skilled in the art that many modifications and others
Embodiments of the invention that come to mind belong to the invention that enjoy the benefit of the teachings presented in the foregoing description and accompanying figures. It is therefore understood that the invention is not limited to the specific embodiments disclosed herein above, and that many modifications and others
Embodiments are intended to be included within the scope of the appended claims. Furthermore, although specific terms are used here, as well as in the claims that follow, they are used only in a general and descriptive sense and not for the purpose of limiting neither the described invention nor the claims that follow.

权利要求:
Claims (19)
[1]
claims
1. resilient floor covering comprising a support member having an uppermost surface and an opposite bottom surface that is configured to substantially rest on the floor when the resilient floor covering is placed in a selected orientation, and wherein the support member comprises at least one support layer, wherein the at least one carrier layer of the carrier part exhibits a carrier composition which has polyolefin elastomers and a filler;
a decorative part having an uppermost surface and an opposite lowermost surface, the decorative part being formed so that it lies above the carrier part such that the uppermost surface of the carrier part is in contact with the lowermost surface of the decorative part, and wherein the decorative part has a layer of paint; and a wear layer having an exposed outer surface portion configured for exposure to the environment and an opposite lowermost surface designed to overlie substantially the decorative portion of the flooring, the exposed outer surface portion of the wear layer further comprising a scratch layer ;
wherein the resilient floor covering exhibits no vinyl polymer material, and wherein the scratch layer shows a micro scratch resistance, which is determined by a change in gloss value in the range from 1 to 3, measured according to Martindale test EN 16094-2012 test A (MSR-A), and by visual assessment of the surface scratching in the range of 1 to 3
B E2017 / 5422, measured according to Martindale test EN 16094-2012 Test B (MSR-B).
[2]
2. Elastic flooring of claim 1, wherein the
Carrier composition has an ethylene-octene copolymer.
Third Elastic flooring from claim 2, in which the Carrier composition between about 65% and about 95% Per Weight of the filler, 4th Elastic flooring from claim 2, in which the Carrier composition between about 75% and about 85% Per Has weight of the filler. 5th Elastic flooring from claim 1, in which the
Carrier composition further comprises crushed glass fibers.
[3]
The resilient floor covering of claim 1, wherein the color layer has at least one dye selected from the group consisting of water-based, soy-based, or solvent-based pigments.
[4]
7. The resilient floor covering of claim 1, wherein the wear layer is positioned adjacent to the decorative part such that the top surface of the decorative part contacts the bottom surface of the wear layer.
[5]
8. Elastic flooring of claim 1, wherein the decorative part has a decorative layer.
[6]
9. Elastic flooring of claim 8, wherein the decorative layer of at least one of: oriented polypropylene (OPP), polyolefin (PO), woven polyethylene (PE), non-woven PE, woven polypropylene (PP), non-woven PP, woven PET, Non-woven PET, woven nylon, non-woven nylon, conventional papers, conventional films, or filled oriented polypropylene (OPP).
B E2017 / 5422
[7]
10. Elastic floor covering of claim 8, wherein the decorative layer of at least one of: heat-stabilized biaxially oriented PET (BOPET), amorphous PET (a-PET), recycled PET (rPET), glycol-modified polyethylene terephthalate (PETG), polyolefin, Cycloolefin copolymer (COC), cycloolefin polymer (COP), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly (methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), polycarbonate, polyethylene (PE), or a copolymer thereof.
[8]
11. The resilient flooring of claim 8, wherein the decorative layer has a thickness of about 1 mil to about 8 mils.
[9]
12. Elastic flooring of claim 9, wherein the decorative layer comprises a film.
[10]
13. The resilient flooring of claim 1, wherein the polyolefin elastomer comprises a polyethylene elastomer, a polypropylene elastomer, or a copolymer of propylene and ethylene, or a combination thereof.
[11]
14. The resilient flooring of claim 1, wherein the polyolefin elastomer is a copolymer of propylene and ethylene.
[12]
15. The resilient flooring of claim 14, wherein the propylene content of the copolymer is at least about 80%.
[13]
16. Elastic flooring of claim 1, wherein the filler calcium carbonate, fly ash, coal fly ash, wollastonite, silica, wood, glass, kaolin, clay, mica, titanium dioxide, recycled fine grains, glass fiber, diatomaceous earth, talc, lime, barite, graphite carbon, composites post-industrial carpet or composite of post-consumer carpet or a combination thereof.
B E2017 / 5422
[14]
17. Elastic flooring of claim 1, wherein the scratch layer comprises polyurethane, or acrylic, or a combination thereof.
[15]
18. The resilient floor covering of claim 1, wherein the scratch layer has a surface hardener,
[16]
19. Elastic floor covering of claim 18, wherein the surface hardening agent aluminate, aluminum oxide, acrylic beads, silicon dioxide, glass spheres, sol-gel aluminum oxide, nylon-orgasol, MF-silica optbeads, polyethylene dispersion, silyl-acrylic-set moist particles, wollastonite, clay , Silyl acrylic polysiloxane, sodium silicate, or a combination thereof.
[17]
20. The resilient flooring of claim 1, wherein the scratch layer has a thickness in the range of about 0.25 to about 3 mils.
[18]
21. The resilient flooring of claim 1, wherein the backing composition comprises between about 10 and about 50 weight percent polymer based on the total weight of the backing composition.
[19]
22. The resilient flooring of claim 1, wherein the polymer comprises from about 50 to about 100 weight percent polyolefin based on the total weight of the polymer.

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法律状态:
2019-03-18| FG| Patent granted|Effective date: 20190214 |

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