Surface covering having gloss in-register and method of making
First Claim
1. A surface covering or surface covering component comprising:
- a) a substrate and b) a substantially homogenous top coat overlying the substrate, the top coat being formed from a radiation curable composition, the top coat comprising an exposed surface that includes a first region with a first concentration of a gloss controlling agent and a second region with a second different concentration of the gloss controlling agent, whereby the exposed surface of the top coat adjacent the first region has a first gloss level and the exposed surface of the top coat adjacent the second region has a second different gloss level.
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Accused Products
Abstract
Surface covering components that include a topcoat layer with different gloss levels in various regions on the top coat layer, and methods of manufacturing such surface covering components, are disclosed. The surface covering components include a coating layer that includes regions that have a relatively higher gloss, and regions with a relatively lower gloss. The differential gloss is provided by coating a substrate with a UV-curable coating composition, subjecting a first region of the surface coating to polymerization under a first set of conditions, and subjecting a second region of the surface coating to polymerization under a second set of conditions. The UV-curable coating compositions include UV-curable components and one or more flatting agents. The different polymerization conditions involve applying various photoinitiators, thermal initiators and/or cure altering agents to some regions of the coated substrate, and not applying these components to other regions of the substrate. The components are applied in the form of a pattern. Regions in contact with these components are cured at different rates in one step or in different steps, for example, sequential UV and EB irradiation or UV irradiation at different wavelengths and/or exposure times. The resulting surface coverings and surface covering substrates have differential gloss in register with the printed and/or sprayed patterns.
15 Citations
54 Claims
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1. A surface covering or surface covering component comprising:
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a) a substrate and b) a substantially homogenous top coat overlying the substrate, the top coat being formed from a radiation curable composition, the top coat comprising an exposed surface that includes a first region with a first concentration of a gloss controlling agent and a second region with a second different concentration of the gloss controlling agent, whereby the exposed surface of the top coat adjacent the first region has a first gloss level and the exposed surface of the top coat adjacent the second region has a second different gloss level. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A surface covering or surface covering component comprising:
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a) a substrate and b) a top coat comprising a first region having a first gloss level and a second region having a second gloss level different from the first region, the top coat overlying the substrate, wherein the top coat is formed from a UV-curable composition comprising a UV curable component and a flatting agent and wherein the different gloss levels are achieved by curing the UV-curable composition using a first polymerization condition in the first region and a second different polymerization condition in the second region. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 39, 40, 41, 42, 43, 44, 45, 47, 48, 49, 50, 51, 53, 54)
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23. A method for making a surface covering or surface covering component with regions of different surface gloss, comprising:
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a) applying a composition comprising a gloss controlling agent to a substrate in a first region to form a pattern, b) coating the substrate with a UV-curable coating composition, wherein the UV-curable composition includes a UV-curable component, c) subjecting the coated substrate to a first polymerization condition to polymerize the UV-curable composition in register with the gloss controlling agent in the pattern, and d) subjecting the coated substrate to a second polymerization condition to polymerize the UV-curable composition not in register with the gloss controlling agent in the pattern.
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38. A surface covering component comprising:
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a) a film, b) a patterned layer comprising a gloss controlling agent overlying the film, c) a top coat overlying the patterned layer, wherein the top coat comprises at least two areas with gloss levels different from one another and at least one of the areas is substantially in register with at least a portion of the design of the patterned layer.
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46. A method for making a surface covering, comprising:
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a) preparing a chemically embossed, mechanically embossed or chemically and mechanically embossed substrate, b) applying a gloss controlling agent selected from the group consisting of a photoinitiator, a cure altering agent, and mixtures thereof to the raised portions of the surface of the embossed substrate, c) coating a radiation curable coating composition onto the resulting embossed substrate, d) subjecting the coated substrate to a first set of conditions to polymerize the radiation curable components in contact with the gloss controlling agent at a rate different than the rate of polymerization of the radiation curable components not in contact with the gloss controlling agent, and e) then subjecting the coated substrate to a second set of conditions to further cure the radiation curable composition, and produce a embossed substrate having a differential gloss surface in register with the embossing pattern.
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52. A method for preparing a surface covering, comprising:
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a) supplying a mechanically-embossable substrate, b) applying a gloss controlling agent selected from the group consisting of a photoinitiator, a cure altering agent, and mixtures thereof to the raised surfaces of an embossing roll, c) mechanically embossing the substrate and transferring the gloss controlling agent to the down areas of the resulting embossed substrate, d) coating a UV-curable coating composition onto the resulting embossed substrate, e) subjecting the coated substrate to a first set of UV irradiation conditions to polymerize the UV-curable components in contact with the gloss controlling agent at a different rate than those not in contact with the gloss controlling agent, and f) subjecting the coated substrate to electron beam irradiation or a second set of UV conditions to further cure all regions of the UV curable composition.
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Specification