Curable coating composition for sheet goods

• US 6,146,711 A
• Filed: 08/05/1997
• Issued: 11/14/2000
• Est. Priority Date: 02/27/1995
• Status: Expired due to Term

• Current Assignee: Tarkett Incorporated (Tarkett Holding GmbH)
• Original Assignee: Domco Industries, Inc.
• Inventors: Courtoy, Jean-Fran.cedilla.ois, Charest, Claude
• Primary Examiner(s): PADGETT, MARIANNE L
• Application Number:
  US08/906,252
• Time in Patent Office: 1,197 Days
• Field of Search: 427/493, 427/498, 427/506, 427/512, 427/520, 427/244, 427/373, 427/393.5, 427/385.5, 156/77, 156/78, 156/79, 156/244.17, 156/244.23, 156/272.2, 156/272.8, 156/273.5, 156/275.5
• US Class Current: 427/493
• CPC Class Codes: C08F 220/10 Esters
• CPC Class Codes: C08F 222/1063 of alcohol terminated polyethers
• CPC Class Codes: C08F 255/00 Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
• CPC Class Codes: C08F 290/147 Polyurethanes; Polyureas
• CPC Class Codes: C08L 27/04 containing chlorine atoms
• CPC Class Codes: C09D 175/16 having terminal carbon-to-carbon unsaturated bonds
• CPC Class Codes: C09D 4/00 Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
• CPC Class Codes: C09D 4/06 Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers

Abstract

A wear layer is applied to a flooring material to yield a product having superior properties. The wear layer is applied to the flooring material using a coating composition comprising (i) a polyvinyl chloride (PVC) resin, (ii) an acrylic or methacrylic compound and (iii) a radiation-reactive urethane oligomer, which composition is substantially or completely free of internal or external plasticizers, heating to heat-cure the coating composition and irradiating the composition to radiation-cure the coating composition.

Claims

1. A process for applying a wear layer to a flooring material, wherein the process comprises applying to the flooring material a coating composition comprising (i) a polyvinyl chloride (PVC) resin, (ii) an acrylic or methacrylic compound and (iii) a radiation-reactive urethane oligomer, where said composition is substantially or completely free of internal or external plasticizers, heating to heat-cure the coating composition and irradiating the composition to radiation-cure the coating composition.

2. A process according to claim 1 wherein the PVC resin is a PVC suspension resin, the coating composition is heat-cured and formed into a laminate before the composition is applied to the material, the laminate is applied to the material and then radiation cured.

3. A process according to claim 1 wherein the PVC resin is a PVC suspension resin and the coating composition is applied to the material before the composition is heat-cured and radiation-cured.

4. A process according to claim 1 wherein the PVC resin is a PVC emulsion resin and the coating composition is applied to the material before the composition is heat-cured and radiation-cured.

5. A process according to claim 1 wherein the material to be coated comprises a foamable PVC plastisol, the coating composition is applied to the foamable PVC plastisol and is heated to cure the coated composition and also to cause the PVC plastisol to foam.

6. A process according to claim 5 wherein after the heating but before the irradiating, the foamed plastisol and heat-cured coating composition are embossed.

7. A process according to claim 1 wherein the PVC resin is a PVC emulsion resin with a relative viscosity between 2.05 and 3.40 and the components of the coating composition are admixed to form a paste and are freed of any entrapped air before the composition is heated.

8. A process according to claim 1 wherein the PVC resin is a PVC suspension resin that has a relative viscosity between 1.56 and 2.52 and the components of the coating composition are admixed with heating to form a dry powder before the composition is heat-cured.

9. A process according to claim 1 wherein the radiation-reactive urethane oligomer is based on an aliphatic polycarbonate polyol.

10. A process for coating a wall covering material or a flooring material, wherein the process comprises:

applying to the wall covering material or the flooring material a heat-curable and radiation-curable coating composition, the coating composition comprising;

(i) a polyvinyl chloride (PVC) resin; and

(ii) an acrylic or methacrylic compound, wherein the coating composition is substantially or completely free from internal or external plasticizers; and

heating to heat-cure the coating composition and irradiating the composition to radiation-cure the coating composition.

11. A process according to claim 10 wherein the PVC resin is a PVC suspension resin and the coating composition is applied to the material before the composition is heat-cured and radiation-cured.

12. A process according to claim 10 wherein the PVC resin is a PVC emulsion resin and the coating composition is applied to the material before the composition is heat-cured and radiation-cured.

13. A process for applying a composition to a wall covering material or a flooring material, the process comprising:

heat-curing the composition and forming the composition into a laminate, the composition comprising,

(i) a polyvinyl chloride (PVC) suspension resin; and

(ii) an acrylic or methacrylic compound, wherein the composition is substantially or completely free from internal or external plasticizers;

applying the laminate to the wall covering material or the flooring material; and

radiation-curing the laminate after application of the laminate to the wall covering material or the flooring material.