Surface covering having gloss in-register and method of making
First Claim
1. A surface covering or surface covering component comprising:
- a) a substrate;
b) a patterned layer overlying the substrate, wherein the pattern layer comprises a first gloss controlling agent, the first gloss control agent being selected from the group consisting of at least one thermal initiator, at least one photoinitiator, at least one photosensitizer, at least one accelerator, at least one inhibitor and combinations thereof; and
c) a crosslinked top coat overlying the patterned layer, the crosslinked top coat comprising a flatting agent and having a first region with a first concentration of the first gloss controlling agent and a second region with a second different concentration of the first gloss controlling agent, wherein other than any gloss controlling agent and the flatting agent, the crosslinked top coat is homogeneous, whereby the first region has a first gloss level and 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.
49 Citations
36 Claims
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1. A surface covering or surface covering component comprising:
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a) a substrate;
b) a patterned layer overlying the substrate, wherein the pattern layer comprises a first gloss controlling agent, the first gloss control agent being selected from the group consisting of at least one thermal initiator, at least one photoinitiator, at least one photosensitizer, at least one accelerator, at least one inhibitor and combinations thereof; and
c) a crosslinked top coat overlying the patterned layer, the crosslinked top coat comprising a flatting agent and having a first region with a first concentration of the first gloss controlling agent and a second region with a second different concentration of the first gloss controlling agent, wherein other than any gloss controlling agent and the flatting agent, the crosslinked top coat is homogeneous, whereby the first region has a first gloss level and the second region has a second different gloss level. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 30)
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22. A surface covering component comprising:
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a) a film having an exposed surface, b) a patterned layer overlying the film on the side of the film opposite the exposed surface, wherein the pattern layer comprises a first gloss controlling agent, the first gloss controlling agent being selected from the group consisting of at least one thermal initiator, at least one photoinitiator, at least photosensitizer, at least one accelerator, at least one inhibitor and combinations thereof, the first gloss controlling agent forming a design, and c) a crosslinked top coat overlying the patterned layer on the side of the pattern layer opposite the film, wherein the crosslinked 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. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 31, 32, 33, 34, 35, 36)
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Specification