Fiber wear layer for flooring and other products

• US 20050176321A1
• Filed: 03/02/2005
• Published: 08/11/2005
• Est. Priority Date: 10/14/2003
• Status: Abandoned Application

• Current Assignee: MW Custom Papers, LLC (Meadwestvaco Corporation)
• Original Assignee: MW Custom Papers, LLC (Meadwestvaco Corporation)
• Inventors: De Oliveira, Inez N., Crette, Stephanie A., Johnson, Mark A.
• Application Number:
  US11/070,609
• Publication Number:
  US 20050176321A1
• Time in Patent Office: Days
• US Class Current: 442/103
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: D21H 27/18 Paper- or board-based structures for surface covering
• CPC Class Codes: E04F 15/10 of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 442/15 Including a foam layer
• CPC Class Codes: Y10T 442/155 Including a paper layer
• CPC Class Codes: Y10T 442/172 Coated or impregnated
• CPC Class Codes: Y10T 442/176 Three or more layers
• CPC Class Codes: Y10T 442/195 Including a foam layer
• CPC Class Codes: Y10T 442/198 Coated or impregnated
• CPC Class Codes: Y10T 442/2361 Coating or impregnation improves stiffness of the fabric other than specified as a size
• CPC Class Codes: Y10T 442/273 : Coating or impregnation provides wear or abrasion resistance
• CPC Class Codes: Y10T 442/277 : Coated or impregnated cellulosic fiber fabric
• CPC Class Codes: Y10T 442/2779 : Coating or impregnation contains an acrylic polymer or copolymer [e.g., polyacrylonitrile, polyacrylic acid, etc.]
• CPC Class Codes: Y10T 442/2787 : Coating or impregnation contains a vinyl polymer or copolymer
• CPC Class Codes: Y10T 442/50 : FELT FABRIC
• CPC Class Codes: Y10T 442/59 : At least three layers

Abstract

A laminar product comprising an overlay and a base layer, the overlay including a fibrous web impregnated with a radiation curable saturating resin, the base layer being a resilient resin layer or a felt or matted layer. In one embodiment, the radiation curable saturating resin includes a reactive silicone acrylate oligomer. Radiation curable compositions containing a silicone acrylate are also disclosed.

Claims

1. A laminar product comprising an overlay and a base layer, the overlay including a fibrous web impregnated with a saturating resin, the base layer being a resilient resin layer, a felt or matted layer, or a wood layer, the saturating resin being a radiation curable resin.

2. The laminar product of claim 1 wherein the fibrous web is a cellulose web.

3. The laminar product of claim 2 wherein the saturating resin is a radiation curable composition containing an ethylenically unsaturated compound curable through free radical induced polymerization.

4. The laminar product of claim 3 wherein, when cured, the overlay provides a hardness of about 3 H to 9 H and/or an abrasion resistance of about 0.01 to 0.08.

5. The laminar product of claim 3 wherein the radiation curable composition includes a silicone acrylate oligomer.

6. The laminar product of claim 5 wherein the radiation curable composition further includes a cyclic polyfunctional acrylate compound.

7. The laminar product of claim 6 wherein the radiation curable composition additionally includes an alkoxylated acrylate compound.

8. The laminar product of claim 3 wherein the radiation curable composition additionally includes a reactive diluent.

9. The laminar product of claim 7 wherein the cyclic acrylate compound is be present in an amount of about 1 to 40% by weight, the alkoxylated acrylate is present in an amount of about 5 to 85%, and the silicone acrylate is present in an amount of about 0.1 to 25% based on the total weight of the radiation curable composition.

10. The laminar product of claim 5 wherein the overlay includes a wear-resistant pigment.

11. The laminar product of claim 10 wherein the base layer is a resilient layer containing a vinyl resin.

12. The laminar product of claim 10 wherein the base layer includes a foamed polymeric layer and a felt or mat layer, wherein the foamed polymeric layer is interposed between the felt layer and the overlay.

13. The laminar product of claim 10 wherein the base layer is wood flooring.

14. The laminar product of claim 10 wherein the wear-resistant pigment is rounded quartz or fused alumina.

15. The laminar product of claim 10 wherein the cellulose web includes alpha cellulose.

16. The laminar product of claim 15 wherein the overlay has a basis weight of about 17 to 30 lbs per 3,000 square feet.

17. The laminar product of claim 10 wherein the laminate is suitable for use as flooring.

18. The laminar product of claim 13, wherein the wood flooring is engineered wood flooring or wood veneer flooring

20. The laminar product of claim 10 wherein the base layer is a composite of limestone and a vinyl resin.

19. A laminar flooring product comprising a base layer of wood and an overlay overlying the base layer, the overlay including a paper web impregnated with a saturating resin, the saturating resin being a radiation curable resin, wherein the resin includes a reactive silicone acrylate oligomer.

21. A radiation curable composition comprising a silicone acrylate and a cyclic polyfunctional acrylate.

22. The composition of claim 21 further comprising an alkoxylated acrylate.

23. The composition of claim 22 wherein the cyclic acrylate compound is present in an amount of about 1 to 40% by weight, the alkoxylated acrylate is present in an amount of about 5 to 85%, and the silicone acrylate is present in an amount of about 0.1 to 25% based on the total weight of the radiation curable composition.

24. The composition of claim 23 wherein the radiation curable composition additionally includes a reactive diluent.

25. The composition of claim 21 wherein the radiation curable composition additionally includes at least one photoinitiator.

26. The composition of claim 21 wherein the radiation curable composition is formulated such that when cured in an overlay, the cured and saturated overlay provides a hardness of about 3 H to 9 H and/or an abrasion resistance of about 0.01 to 0.08.

27. The composition of claim 23 wherein alkoxylated monomers may be monofunctional or polyfunctional and contain about 1 to 15 carbon atoms in the alkoxy group

28. A method for applying a wear layer to a substrate comprising applying a radiation curable composition including a silicone acrylate and a cyclic polyfunctional acrylate to the surface of the substrate, and exposing the layer to actinic radiation to cure the layer.

29. The method of claim 28 wherein the radiation curable composition is first impregnated into a paper web and the impregnated paper web is applied to the surface of the substrate.