RESILIENT FLOORING COMPOSITIONS

• US 20120276348A1
• Filed: 01/07/2011
• Published: 11/01/2012
• Est. Priority Date: 01/07/2010
• Status: Abandoned Application

• Current Assignee: Robert N. Clausi, Salvatore A. Diloreto
• Original Assignee: Robert N. Clausi, Salvatore A. Diloreto
• Inventors: Clausi, Robert N., Diloreto, Salvatore A.
• Application Number:
  US13/519,964
• Publication Number:
  US 20120276348A1
• Time in Patent Office: Days
• US Class Current: 428/196
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2317/125 impregnated with thermosetting resin
• CPC Class Codes: B32B 2319/00 Synthetic rubber
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 29/002 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 37/06 characterised by the heating method
• CPC Class Codes: E04F 13/002 made of webs, e.g. of fabrics, or wallpaper, used as coverings or linings of a number of similar elements carried by a common web E04F13/0862; paperhanging, tapestry work B44C7/00
• CPC Class Codes: E04F 15/107 composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24934 including paper layer
• CPC Class Codes: Y10T 428/24983 Hardness
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31725 Of polyamide
• CPC Class Codes: Y10T 428/31783 Paper or wood
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/3179 Next to cellulosic
• CPC Class Codes: Y10T 428/31826 Of natural rubber
• CPC Class Codes: Y10T 428/31841 Next to cellulosic
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31895 : Paper or wood
• CPC Class Codes: Y10T 428/31931 : Polyene monomer-containing
• CPC Class Codes: Y10T 428/31942 : Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31964 : Paper
• CPC Class Codes: Y10T 428/31993 : Of paper
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3472 : Woven fabric including an additional woven fabric layer
• CPC Class Codes: Y10T 442/3927 : Including a paper or wood pulp layer

Abstract

Resilient flooring materials made from impregnated papers or foils and core materials are provided. As well, the methods for producing such products are provided. In particular, panels, with a layered structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated decorative layer with printed graphics or a wood veneer decorative layer, a core material made up of one or more heat-activated resin-impregnated papers or other materials including linoleum, natural or synthetic rubber, cork, flexible natural fiber composites or other core materials, and a heat-activated resin impregnated paper backing layer. The heat-activated resin also acts to waterproof each of the layers and abrasion particles may be incorporated to improve wear properties. The panels may also be formed into three-dimensional products.

Claims

1. A resilient material, and preferably a resilient flooring material, comprising a resilient, flexible panel having multiple layers, whereby one or more layers comprising the resilient layer panel structure are made from papers, foils or woven materials, which papers, foils or woven materials are impregnated with, or coated with, an elastomeric resin, film or material.

2. A resilient flooring material as claimed in claim 1 wherein flexible panel is a floor covering.

3. A resilient flooring material as claimed in claim 2 wherein said floor covering is a floor panel.

4. A resilient flooring material as claimed in claim 1 wherein said layers of said panel comprise:

(i) an optional impregnated and coated wear paper layer that has a translucent surface;

(ii) an impregnated and coated decorative paper layer that has a printed surface;

(iii) a core layer made from a variety of materials; and

/or

(iv) a backer layer consisting of impregnated and coated paper.

5. A resilient flooring material as claimed in claim 4 additionally comprising one or more of the following layers, namely:

(i) a felt layer;

(ii) a core layer of linoleum, cork, or natural or synthetic rubber;

(iii) a natural or synthetic rubber backing layer; and

/or

(iv) a pressure sensitive adhesive layer.

6. A resilient flooring material as claimed in claim 1 wherein said papers, foils or woven materials are impregnated with, or coated with, an elastomeric resin, and wherein said elastomeric resin is a thermosetting or thermoplastic resin.

7. A resilient flooring material as claimed in claim 6 wherein said thermosetting or thermoplastic resin is PE, all grades (LLDPE, LDPE, MDPE, HDPE);

Polyurethane;

Polypropylene;

Ethylene vinyl acetate;

Ethylene vinyl alcohol;

Polyester;

Polyolefin (TPO);

Urea and Urea-modified thermoset resins;

modified Melamine-based thermoset resins;

Phenolic resins;

ESI - ethylene styrene interpolymer or any of the styrene acrylic copolymers and Acrylic resins;

rubber based materials, NBR (nitrile Butadiene), SBR (styrene butadiene), CR (chloroprene), silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated natural and synthetic latexes, or combinations thereof and therebetween.

8. A resilient flooring material as claimed in claim 1 comprising two or more papers, foils or woven materials layers, wherein each of the paper, foils or woven material layers are impregnated with, or coated with, an elastomeric material.

9. A resilient flooring material as claimed in claim 8 wherein each layer of paper, foil or woven material is impregnated with, or coated with, an elastomeric material, and optionally, wherein said elastomeric materials used on each layer have differing hardness.

10. A resilient flooring material as claimed in 1 additionally comprising a transparent wear layer comprising a thermoplastic material.

11. A resilient flooring material as claimed in claim 10 wherein said wear layer is PTO, polyethylene or polypropylene.

12. A method for the production of a resilient material, and preferably a resilient flooring material, comprising preparing multiple component layers, and pressing said component layers together, wherein one or more layers comprising the resilient material are made from papers, foils or woven materials, which papers, foils or woven materials are impregnated with, or coated with, an elastomeric resin, film or material.

13. A method as claimed in claim 12 wherein said papers, foils or woven materials are saturated with said elastomeric resin, film or material.

14. A method as claimed in claim 12 wherein said elastomeric material is applied to a paper-based layer, and said resultant core panel is subsequently placed in a vacuum chamber so that said elastomeric material impregnates said layer.

15. A method as claimed in claim 12 wherein said elastomeric material is a water-based elastomeric solution that is applied to a paper-based layer, and said water-based elastomeric solution penetrates the said paper-based layer.

16. A method as claimed in claim 15 wherein said papers are processed in continuous roll form.

17. A method as claimed in claim 16 wherein said papers are processed in a VITS impregnation line.

18. A method as claimed in claim 12 wherein said resilient flooring material comprises several independently treated loose flexible layers, which layers are placed in a heated press and pressed under pressure for a period of time, removed from the press and subsequently die cut or machine cut to a specific size.

19. A method as claimed in claim 12 wherein said papers, foils or woven materials are impregnated with an elastomeric resin, and wherein said elastomeric resin is a thermosetting or thermoplastic resin.

20. A method as claimed in claim 19 wherein said thermosetting or thermoplastic resin is PE, all grades (LLDPE, LDPE, MDPE, HDPE);

Polyurethane;

Polypropylene;

Ethylene vinyl acetate;

Ethylene vinyl alcohol;

Polyester;

Polyolefin (TPO);

Urea and Urea-modified thermoset resins;

modified Melamine-based thermoset resins;

Phenolic resins;

ESI—

ethylene styrene interpolymer or any of the styrene acrylic copolymers and Acrylic resins;

rubber based materials, NBR (nitrile Butadiene), SBR (styrene butadiene), CR (chloroprene), silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated natural and synthetic latexes, or combinations thereof and therebetween.