CN110023430A - 具有分散在其中的耐磨添加剂的耐磨层的表面覆盖物及其制造方法 - Google Patents
具有分散在其中的耐磨添加剂的耐磨层的表面覆盖物及其制造方法 Download PDFInfo
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- CN110023430A CN110023430A CN201780073972.5A CN201780073972A CN110023430A CN 110023430 A CN110023430 A CN 110023430A CN 201780073972 A CN201780073972 A CN 201780073972A CN 110023430 A CN110023430 A CN 110023430A
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- Prior art keywords
- wear
- wearing layer
- diamond
- surface covering
- composition
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Abstract
一种耐磨组合物,包括聚合物热熔粘合剂系统,所述聚合物热熔粘合剂系统包括至少一种耐磨添加剂,所述耐磨添加剂包括分散在其中的金刚石颗粒。一种表面覆盖物,包括基层、耐磨层和可选的顶涂层。耐磨层层压在基层上。耐磨层可以通过将包括金刚石在内的多个耐磨添加剂颗粒分散到液体中形成稳定的液体分散液、将稳定的液体分散液混合到聚合物树脂中形成混合物、挤压混合物从而形成耐磨层。
Description
相关申请的交叉引用
本申请声称于2016年10月5日提交的第62/404,534号美国临时专利申请的权益,其内容在这里以援引方式全部并入本文中。
技术领域
本发明涉及具有含耐磨金刚石颗粒的耐磨层的表面覆盖物、耐磨层和表面覆盖物的制造方法以及由此制成的产品。
背景技术
为了改善磨损,表面覆盖物通常在其最外表面上提供一层面漆。传统的面漆通常由辐射可固化涂料组成,如紫外线可固化涂料。辐射可固化涂料通常是低聚物或单体的树脂基混合物,在通过辐射固化施加到表面覆盖层后固化或交联。辐射固化使树脂聚合,形成具有优异耐磨性和耐化学性的高光泽或低光泽涂料。为了进一步增强顶涂层的性能,顶涂层还具有耐磨颗粒,例如分散在整个涂料中的氧化铝。
由于上述顶涂层通常在表面覆盖物完全构造完成后被施涂和固化,因此在表面覆盖物构造后,顶涂层的施涂和固化需要额外的处理步骤。此外,用紫外线(UV)灯固化面漆需要额外的费用。此外,面漆化学性质的独特性,特别是分散有耐磨颗粒时,需要额外的混合和固化步骤。这些额外的步骤可能会导致成本增加,以及由于额外处理表面覆盖物而导致的材料损失增加。因此,需要开发一种表面覆盖物,该表面覆盖物的最外层表面具有额外的耐磨性和耐化学性,易于构造,从而消除不必要的加工步骤,降低成本。
发明内容
在本发明的一个方面中,提供了一种耐磨热熔涂料组合物,其包括粘合剂成分(含有热熔聚合物)和耐磨添加剂(含有金刚石颗粒)。
在本发明的另一方面,提供了一种具有增强耐磨性的地板覆盖物,其包括:
基板;以及
涂层,包括热熔聚合物粘合剂组合物和耐磨添加剂,所述耐磨添加剂包括分散在其中的金刚石颗粒,其中所述金刚石颗粒为粘合剂组合物总重量的约1%到约50%。
在本发明的另一方面中,提供了一种表面覆盖物,其包括层压板结构,该层压板结构包括:
基层;以及
在所述基层上的耐磨层,所述耐磨层包括聚合物热熔粘合剂和分散在所述聚合物粘合剂中的耐磨颗粒;所述耐磨颗粒包括金刚石。
在本发明的另一方面,提供了一种形成表面覆盖物的方法,其包括:
将聚合物粘合剂和包括金刚石在内的耐磨颗粒混合,形成耐磨组合物;
由所述耐磨组合物形成涂料组合物;和
将薄膜施涂到基层上;
其中,所述薄膜是通过将所述耐磨组合物挤压或压延到所述薄膜中的至少一种来形成的。
在本发明的另一方面,提供了一种表面覆盖物,其包括与第二表面相对的第一表面,该表面覆盖物进一步包括层压板结构,包括:基层;在基层顶部的耐磨层,该耐磨层具有从上表面到耐磨层下表面测量的第一厚度。所述耐磨层包括聚合物热熔粘合剂和至少一种耐磨添加剂,所述耐磨添加剂包括分散在所述聚合物粘合剂中的金刚石颗粒;以及可选地在所述耐磨层顶部的顶涂层,所述顶涂层具有从所述顶涂层的上表面到所述顶涂层的下表面测量的第二厚度。表面覆盖物作为地板覆盖物特别有用,包括砖、薄板和层压板。
在本发明的另一方面,提供了一种形成表面覆盖物的方法,其包括:将聚合物热熔粘合剂和至少一种耐磨添加剂混合在一起,以形成耐磨组合物,所述耐磨添加剂包括金刚石颗粒;
由所述耐磨组合物形成薄膜,并将所述薄膜施涂到基层上;其中,所述薄膜是通过将所述耐磨组合物挤压或压延到所述薄膜中的至少一种来形成的。
在本发明的另一方面,提供了一种表面覆盖物,其包括层压板结构,所述层压板结构包括:具有与所述下表面相对的上表面的基层;位于所述基层上部的耐磨层,所述耐磨层包括聚合物热熔粘合剂和至少一种耐磨添加剂,所述耐磨添加剂包括金刚石颗粒;以及在耐磨层上的顶涂层,所述顶涂层最好是连续层并且最好基本上不含所述耐磨添加剂颗粒。
在本发明的另一方面,提供了一种表面覆盖物,其包括层压板结构,该层压板结构包括:
具有与下表面相对的上表面的基层;
在所述基层上的耐磨层,所述耐磨层包括聚合物粘合剂,包括聚氨酯热熔树脂和含有金刚石颗粒的耐磨添加剂;以及
可选的在所述耐磨层上的顶涂层,所述顶涂层为连续层并且基本上不含所述耐磨颗粒。
附图说明
图1是根据本发明实施例的表面覆盖物的结构示意图;
图2是本发明的替代实施例的示意图,其显示了具有顶涂层的表面覆盖物;
图3是本发明的另一个替代实施例的示意图,其显示在其背面具有油墨图案的印刷层的表面覆盖物;并且
图4是本发明的又一个替代实施例的示意图,其显示其上表面上具有油墨图案的印刷层的表面覆盖物。
具体实施方式
就本发明而言,以下定义适用:
“平均直径”是通过测量每件材料(如金刚石材料)的直径,然后计算平均值。如果材料(例如金刚石材料)的直径不同,例如,如果材料(例如金刚石材料)不是球体,则通过测量每件材料(例如金刚石材料)的最长直径,然后计算平均直径。应注意,任何涉及材料的计算(例如,材料块之间的距离、某些材料与层表面的距离等)应使用材料的相关边缘,而不是材料的中心。
“涂料”或“涂层”是指已经施加到表面(例如基板)上然后被固化的化合物。“涂料”可指单个涂层或多个涂层总称。涂层在组成、平均厚度等方面可以彼此相同或不同。
“固化”或“被固化”或类似的方法是指通过交联形成聚合物材料,从而产生诸如(但不限于)增加的粘度和硬度等特性的过程。固化过程可通过几种方法开始,例如,加热和/或实施辐射,例如(但不限于)光,例如可见光或UV光。“完全固化”或类似的说法意味着所有聚合物材料都已经交联。“基本上完全固化”或类似的说法意味着绝大多数聚合物材料具有交联,因此很难或不可能确定是否发生了“完全固化”。“部分固化”或“部分完全固化”或类似的说法意味着固化过程已经开始,但尚未达到“完全固化”或“基本完全固化”的定义。
“分散剂”是在固化前作用于至少在整个组合物中分布或协助分布耐磨材料的任何化学或化合物。
“地板覆盖物”是任何在建筑操作中可能有助于创建地板表面的基板。形成地板覆盖物的基板可以涂有至少一层涂层,也可以不涂。
“基板”是能够在其上施加一层或多层涂层的任何材料。在某些情况下,涂有涂层的基板可被视为形成另一基板。例如,基板可以是,例如,乙烯基砖。然而,表面有涂层的乙烯基砖也可被视为基板。
其他相关信息和/或定义可在与本申请同时或近似提交的几个其他申请中找到,其代理参考编号为2589-21P(美国临时申请编号62/404479,于2016年10月5日提交,标题为“包含树脂、固化系统和金刚石颗粒的地板涂料及其制备方法),2589-22P(美国临时申请编号62/404389,申请日期2016年10月5日,标题为“耐磨性试验”),2589-23P(美国临时申请编号62/404445,申请日期2016年10月5日,标题为“包括金刚石和阳离子固化树脂系统或硫醇-烯可固化系统的涂料组合物”)和2589-24P(美国临时申请编号62/404503,申请日期2016年10月5日,标题为“用于地板的含金刚石颗粒的LED可固化涂料及其制备方法”),每个都通过参考引用全部并入本文中。
图1显示根据本发明实施例的表面覆盖物1。本文所示和描述的表面覆盖层1可以是弹性表面覆盖物,其可以例如以砖或连续板的形式提供。如图1所示,所述表面覆盖物1包括基层2和耐磨层3。所述耐磨层3具有至少一种耐磨添加剂,所述耐磨添加剂包括分散在所述耐磨层4中的金刚石颗粒,并且在耐磨层3的底面上印刷油墨图案5。然而,本领域技术人员应了解,表面覆盖物1不限于本文所示和描述的结构。例如,表面覆盖物1可包含额外的基层、薄膜层和/或顶涂层。此外,基层2和耐磨层3的厚度可根据表面覆盖层1的所需特性而变化。
表面覆盖物的基层
本发明包括具有基层和耐磨层的层压板结构。基层2可具有约35-170mils(密耳)的厚度,并且包括聚合物树脂,其用作填料、增塑剂、稳定剂、加工助剂和颜料等附加组分的基层粘合剂。例如,基层粘合剂可以是聚合物树脂,例如乙烯基树脂,与增塑剂、稳定剂和加工助剂混合。聚合物树脂可包括例如均聚物、共聚物、三元共聚物或其组合。均聚物可包括例如聚氯乙烯、聚醋酸乙烯酯、聚丙酸乙烯酯、聚丁酸乙烯酯、聚偏二氯乙烯、聚丙烯酸乙烯酯、聚丙烯酸乙酯、聚丙烯酸甲酯、聚丙烯酸丙酯、聚丙烯酸丁酯、聚乙烯、聚丙烯或其混合物。该共聚物可包括(例如)聚氯乙烯/聚醋酸乙烯酯、偏二氯乙烯/氯乙烯、甲基丙烯酸甲酯/氯乙烯、丙烯酸甲酯/丙烯酸乙烯酯、丙烯酸乙酯/丙烯酸丁酯共聚物、乙烯-丙烯共聚物、乙烯-苯乙烯共聚物或其混合物。三元聚合物可包括例如聚氯乙烯/聚醋酸乙烯/一氧化碳或聚氯乙烯/聚醋酸乙烯/丙烯酸聚合物。可替换地,基层粘合剂可以是,例如,热塑性聚酯树脂,包括至少一种可回收或可再生组合物。其他基层粘合剂可包括聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸乙二醇酯(PETG)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PPT)或热塑性离聚物树脂,例如来自E.I.du Pont de Nemours and公司的SURLYN。聚合物树脂也可包括例如由可再生聚酯改性的回收材料,例如回收聚对苯二甲酸乙二醇酯(PET)或聚对苯二甲酸丁二醇酯(PBT)。
层压板结构的每一层可包括各种添加剂,例如增塑剂、稳定剂、催化剂、改性剂、颜料、染料、着色剂填料等。
增塑剂可包括例如酯型增塑剂,例如邻苯二甲酸盐、非邻苯二甲酸盐、磷酸盐、苯甲酸盐、改性苯甲酸盐、酒石酸盐、癸二酸盐、己二酸盐、柠檬酸盐、己酸盐、大豆酸盐、偏苯三甲酸盐、磺酸盐、橡胶增塑剂,例如丁二烯-苯乙烯共聚物、丁二烯-乙烯基乙酸酯共聚物或乙烯-醋酸乙烯酯,或其他起增塑剂作用的材料,例如作为环氧化干燥油,芳香烃凝聚物和氯化石蜡。可使用的增塑剂的量可在使用该增塑剂的层的重量约0%至约20%之间变化。
如果使用某些柔软的乙烯基树脂,例如含有大量丙烯酸乙酯的聚合物,则不需要增塑剂。该稳定剂可包括例如混合金属稳定剂,例如钙锌组合物。加工助剂可包括(例如)烃树脂、聚苯乙烯树脂、冲击改性剂、流动改性剂或熔融促进剂,例如丙烯酸共聚物或聚氧化乙烯。
填料可包括例如无机或有机材料,例如碳酸钙、碳酸镁、二氧化硅、硅藻土、白云石、粘土或其混合物。填料可以是可回收或可再生材料。可选颜料可包括(例如)二氧化钛、氧化铁、酞菁蓝、酞菁绿、偶氮红、苯并黄、炭黑或其混合物。
例如,基层2的配方可含有约5%到约80%重量的粘合剂,优选约10%到约60%重量的粘合剂,以及更优选约15%到约35%重量的粘合剂。此外,例如,基层2含有约20%至约95%重量的填料,优选约40%至约90%重量的填料,以及更优选约65%至约85%重量的填料。
耐磨组合物和层
耐磨层3可为包含聚合物热熔粘合剂系统的涂料组合物,该聚合物热熔粘合剂系统具有分散在其中的至少一种耐磨添加剂,所述耐磨添加剂包括金刚石颗粒4。耐磨层3可具有约1-40mils、较佳约2mils至约12mils、及更佳约2至约4mils的厚度。聚合物热熔粘合剂系统可以包括,例如,与添加剂包装和增塑剂混合的聚合物热熔树脂。在本发明的一个特别有用的方面中,聚合物热熔树脂可以是具有由聚氨酯、聚醚、聚酯、聚醚酯、聚酯醚、聚烯烃、聚己内酯、聚丁二烯、聚碳酸酯、聚缩醛、聚酯酰胺、苯乙烯-丁二烯-苯乙烯(SBS)、环氧树脂、聚硫醚或组合物制备的具有主链的树脂。理想情况下,热熔树脂是一种反应性热熔树脂,这意味着它具有反应性基团,即使在热熔被冷却并物理凝固后,也能起到聚合作用。例如,热熔可能具有存在的水分固化基团,一旦热熔成型为所需形式,这些基团可能会与周围的环境水分反应以交联。存在于热熔粘合剂系统上的此类反应基团可选自异氰酸酯基团、烷氧基、硅醇基团及其组合。
可用于本发明的热熔胶的实例包括但不限于美国专利4,946933、美国专利5,166,302、专利6,015,865、专利8,163,824、美国专利9,023946、专利申请公开文本US20030010442A1中所述的那些;所有这些都通过参考援引全部并入本文中。
期望的是,热熔粘合剂是一种含有反应性异氰酸酯基团的聚氨酯聚合物,该聚合物通过水分固化。
热熔粘合剂也可以是含有耐磨添加剂的透明层,然后可以层压到另一层或基板上。透明层和非透明层的组合也可能有用。
耐磨添加剂可以通过将添加剂混合至热熔以添加到热熔粘合剂中,或者可以将添加剂喷洒到热熔树脂的表面,并通过加热和压力(例如压延或层压)嵌入热熔中,例如使用平床压力机。
分散在聚合物热熔中的金刚石添加剂包括但不限于金刚石颗粒、金刚石粉尘、金刚石碎片、金刚石碎块和整个金刚石,或上述各项的组合。在相关方面,金刚石材料的平均直径可在纳米范围或微米范围内。例如,当在纳米颗粒范围内时,平均直径可在约0.1nm到约1000nm范围内;优选地在约0.2nm到约900nm范围内;更优选地在约0.5nm到约800nm范围内;甚至更优选地在约1nm到约600nm范围内;甚至更优选地在约2nm到约500nm范围内;并且最优选地在约10nm至约500nm、约20nm至约500nm、约25nm至约250nm、约35nm至约175nm、约50nm至约150nm、约75nm至约125nm或约20nm至约40nm。
在微米范围内,金刚石添加剂的平均直径可在约0.01μm至约100μm的范围内;优选在约0.1μm至约75μm的范围内;更优选在约0.5μm至约50μm的范围内;更优选在约0.75μm至约25μm的范围内;更优选在约m约1μm至约10μm;最优选约1μm至约5μm,约5μm至约10μm,约2.5μm至约7.5μm,或约6μm至约10μm。
耐磨粒径窄分布,标准偏差小于平均粒径的35%。在本发明的一些方面中,平均耐磨涂层厚度与平均耐磨添加剂粒径的比率在0.6:1到2:1之间。
基于耐磨涂料组合物的总重量,包括金刚石颗粒的耐磨添加剂颗粒的存在量可在约1%到约50%、期望约1%到约20%、甚至更期望约2wt.%到约6wt.%范围内。
为了测定wt.%,可测试固化涂层的样品尺寸。样品可为任何尺寸,例如1cm2、10cm2、100cm2或任何其他可用于测试的尺寸。在统计上,被测涂层样品的厚度应与其余涂层的平均厚度相同。
还可包括其他耐磨添加剂,包括多种形式或尺寸的金刚石添加剂。第二种耐磨添加剂可以是莫氏硬度值至少为6的任何材料,包括但不限于氧化铝和长石,或两者的组合。其中一种耐磨材料的平均直径可以在纳米范围内,而另一种耐磨材料的平均直径可以在微米范围内。可替换地,两种耐磨材料可以具有纳米范围的平均直径,或者两种耐磨材料可以具有微米范围的平均直径。
热熔粘合剂可进一步包括固化系统,所述固化系统包括一种或多种增塑剂、催化剂、稳定剂、改性剂、加工助剂、内部和/或外部润滑包、紫外线吸收剂、着色剂、颜料、其他专用添加剂或其任何组合,例如本文所述的与基层有关的那些。
对于包含聚氨酯树脂的聚合物热熔粘合剂系统,添加剂包装可包括例如稳定剂、改性剂、丙烯酸加工助剂、内外润滑剂包装、紫外线吸收剂、着色剂、其他专用添加剂或其任何组合。
当存在稳定剂时,其可以聚合热熔树脂(phr)的每100份约0.7到约3重量份的水平并入并且可以包括例如热稳定剂,例如有机锡、钙锌或其他金属盐。
热熔树脂改性剂可存在于薄膜中,例如,以每百份重量的聚合物热熔树脂(phr)约4至约15份的水平存在,并且可包括例如冲击强度改性剂,例如甲基丙烯酸甲酯-丁二烯-苯乙烯(MBS)、丙烯腈-丁二烯-苯乙烯(ABS)或所有丙烯酸。丙烯酸加工助剂可存在于薄膜中,例如,以每百份重量的聚合物树脂(phr)的约1-3份的水平存在。内部和外部润滑剂包可以存在于薄膜中,例如,以每百份重量的聚合物热熔树脂(phr)约0.2至约1.5份的水平存在,并且可以包括例如甘油单油酸酯、甘油酯或酯蜡。紫外线吸收剂可存在于薄膜中,例如,其水平为每百份重量的聚合物热熔树脂(phr)约0.0至约0.8份。着色剂可包括例如透明或填充二氧化钛不透明着色剂或透明纯净着色剂。
在本发明的一个方面中,薄膜可以是刚性膜,并且更优选刚性乙烯基膜。刚性膜在本领域中通常被称为不含或基本上不含增塑剂的膜,例如,每百份重量的聚合树脂(phr)包含少于5份的增塑剂。然而,本领域技术人员应当知悉该薄膜可替换为半刚性膜或柔性膜。本文将半刚性膜定义为每百份重量含约5至约10份增塑剂的聚合物热熔树脂(phr)膜。柔性膜在本文中定义为每百份重量的聚合物热熔树脂(phr)中含有超过约10份增塑剂的膜。
分散于薄膜的聚合物热熔粘合剂系统中的耐磨添加剂颗粒4包括金刚石颗粒及可选地额外耐磨添加剂,例如氧化铝(AI2O3)颗粒、结晶类碳化硅、硬质塑料、强化聚合物、尼龙、有机物或其任何组合。
可通过将耐磨颗粒4分散于相容液体中以形成稳定液体分散液来制备耐磨层3。例如,液体可以是聚合物热熔粘合剂系统的液体组合物,例如增塑剂或添加剂包装的液体组合物。随后可使用高速混合器将稳定液体分散液与聚合物热熔树脂以及聚合物热熔粘合剂系统的任何剩余组分混合到温度约为60-90摄氏度以形成混合物。含有聚合物热熔粘合剂系统和耐磨颗粒4的混合物经热压缩、熔融和配制,以及优选挤压或连续混合到约160-200摄氏度的温度。然后,优选将混合物压光以形成耐磨层3。对于包含乙烯基树脂的耐磨层3,压延温度可在约190-225摄氏度范围内。由于混合、配制、挤压和压延混合物以形成薄膜的过程在本领域内是众所周知的,因此省略了对其的进一步描述。
如图1所示,耐磨层3形成后,用油墨图案5印刷耐磨层3。在本文所示和描述的实施例中,耐磨层3在其背面具有油墨图案5。然而,本领域技术人员应当了解,作为耐磨层3在背面提供油墨图案5的补充或者可替换方案,还可替换为透明或在其顶面上提供油墨图案。耐磨层3也可以选择机械和/或化学压花。然后将耐磨层3层压到基层2上。例如,可以使用传统的标准叠层压机或传统的滚轧压入式叠层机将耐磨层3层压到基层2上。
在本发明的某些方面,本发明提供一种地板覆盖物,其包括根据上述任何方法制备的基板。基板可为(但不一定限于)瓷砖(例如乙烯基瓷砖、瓷砖、瓷砖和木瓷砖)、油毡、层压板、工程木材、木材(例如,灰、桦木、樱桃、异国情调、胡桃木、枫木、橡木、胡桃木和胡桃木)、软木、石头、竹子、乙烯基板,以及上述任何材料的组合。
在本发明的另一方面,耐磨材料可从涂层的顶面突出距离约为平均涂层厚度的1-50%。平均涂层厚度与耐磨材料平均直径之比有时可在约0.6:1至约2:1范围内。在某些情况下,两块耐磨材料之间的平均距离约为20-75μm。
图2显示本发明的替代实施例。如图2所示,所述耐磨层3具有顶涂层6。顶涂层6以液体或流动形式涂覆在耐磨层3上,厚度约为1mil,然后被固化。已知通过暴露于受控辐射(例如紫外线或电子束辐射)来固化顶涂层6。顶涂层6可为例如辐射固化涂层,例如丙烯酸聚氨酯或丙烯酸聚酯。或者,所述顶涂层(未显示)可以是包含生物基组分的辐射可固化的生物基涂层。例如,生物基组分可以是生物基多元醇、丙烯酸生物基多元醇或生物基树脂,其衍生自可再生和/或生物基材料,例如植物油、聚酯、聚酯醚、植物油、玉米、纤维素、淀粉、糖或糖醇。顶涂层6提供了额外的抗标记性,并可刮到表面覆盖物1的最外表面。
图3-4显示了本发明的另一个替代实施例。如图3-4所示,表面覆盖嵌体还设有印刷层7。印刷层7可为例如刚性膜或半刚性膜,其包含例如与添加剂包装和增塑剂混合的聚合树脂。
聚合物粘合剂系统包括例如与添加剂包装和增塑剂混合的聚合物树脂。聚合物树脂可以是例如乙烯基树脂,例如聚氯乙烯。或者,聚合物树脂可以是,例如,聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸乙二醇酯(PETG)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PPT)或热塑性离聚物树脂,例如来自E.I.Du Pont de Nemours and公司的SURLYN。聚合物树脂也可包括例如由可再生聚酯改性的回收材料,例如回收聚对苯二甲酸乙二醇酯(PET)或聚对苯二甲酸丁二醇酯(PBT)。增塑剂可包括例如不饱和甘油酯或邻苯二甲酸酯。添加剂包装可包括例如稳定剂、改性剂、丙烯酸加工助剂、内外润滑剂包装、紫外线吸收剂、着色剂、其他专用添加剂或其任何组合。
如图3-4,印刷层7使用墨水图案5而不是耐磨层3打印。在图3中,印刷层7的背面具有油墨图案5。在图4中,印刷层7的顶面上设有油墨图案5。然而,本领域技术人员应了解,印刷层7可交替地设置在印刷层7的背面和顶面上。印刷层7也可选地为机械和/或化学压印。此外或者可替换地,耐磨层3也可以在其背面和/或顶面上提供印刷层,和/或可以机械和/或化学压花。印刷层7层压到基层2与耐磨层3之间的基层2上。例如,使用传统的标准叠压机或传统的滚轧型压合机,将印刷层7层压到基层2和耐磨层3之间的基层2上。
根据本文所述的本发明的一些实施例,在表面覆盖物1中,耐磨层3可以形成表面覆盖物1的最外表面,并且可以包括分散在其中的耐磨添加剂4,所述耐磨添加剂4包含金刚石颗粒,所述金刚石颗粒为耐磨层3提供附加的耐磨和耐化学性能。因此,根据本发明的表面覆盖物1可以容易地构造成具有额外的耐磨性和耐化学性的最外表面,同时消除不必要的加工步骤并降低成本。
上述说明了实施该发明的一些可能性。许多其他实施例在本发明的范围和精神范围内是可能的。例如,尽管本文所示和描述的耐磨层3与地板表面相关的表面覆盖物1结合使用,但本领域技术人员将了解耐磨层可与其他类型的表面覆盖物结合使用,例如墙纸、台面、汽车结构、家具表面、保护外壳表面等,仍然具有相同的附加耐磨性和耐化学性。因此,其目的在于将上述描述视为说明性的而非限制性的,并且本发明的范围由所附权利要求书及其全部等效范围给出。
Claims (37)
1.一种耐磨热熔涂料组合物,包括:
一种粘合剂组合物,其包含热熔聚合物和包含金刚石颗粒的耐磨添加剂。
2.根据权利要求1所述的耐磨热熔涂料组合物,其中所述金刚石颗粒的平均粒径约为0.1nm至1000nm。
3.根据权利要求1所述的耐磨热熔涂料组合物,其中所述金刚石颗粒的平均粒径约为0.1μm到约75μm。
4.根据权利要求1所述的耐磨热熔涂料组合物,其中所述金刚石颗粒以总耐磨组合物总重量约1%到约50%的量存在。
5.根据权利要求1所述的耐磨热熔涂料组合物,其中所述热熔聚合物是含有水分固化基团的聚氨酯热熔涂料。
6.根据权利要求1所述的耐磨热熔涂料组合物,其中所述水分固化基团为异氰酸酯基团。
7.一种具有增强耐磨性的地板覆盖物,包括:
基板;以及
涂层,包括热熔聚合物粘合剂组合物和耐磨添加剂,所述耐磨添加剂包括分散在其中的金刚石颗粒,其中所述金刚石颗粒以粘合剂组合物总重量的约1%到约50%的量存在。
8.根据权利要求7所述的地板覆盖物的组合物,其中金刚石颗粒的平均粒径为约0.1nm至约1000nm。
9.根据权利要求7所述的地板覆盖物的组合物,其中所述金刚石颗粒的平均粒径约为0.1μm至75μm。
10.一种包括层压板结构的表面覆盖物,其包括:
基层;以及
耐磨层,位于所述基层上部,所述耐磨层包括聚合物热熔粘合剂和分散在所述聚合物粘合剂中的耐磨颗粒;所述耐磨颗粒包括金刚石。
11.根据权利要求10所述的表面覆盖物,还包括在所述耐磨层上的顶涂层。
12.根据权利要求10所述的表面覆盖物,其中所述基层厚度与所述耐磨层厚度的比值为约1:1至约1:40。
13.根据权利要求10所述的表面覆盖物,其中所述耐磨厚度与所述顶涂层的比值为约1:1到约1:12。
14.根据权利要求10所述的表面覆盖物,其中所述层压板结构进一步包括位于所述基层和所述耐磨层之间的印刷层。
15.根据权利要求10所述的表面覆盖物,其中所述印刷层是压花的。
16.根据权利要求110所述的表面覆盖物,其中所述耐磨颗粒的尺寸在约10nm到约500nm之间。
17.根据权利要求1所述的表面覆盖物,其中所述耐磨颗粒以所述耐磨层重量的约1%到约50%的量存在。
18.根据权利要求10所述的表面覆盖物,其中所述层压板结构的厚度在35mils到170mils的范围之间。
19.根据权利要求1所述的表面覆盖物,其中所述耐磨层的第一厚度在约1mil到约40mils的范围之间。
20.一种形成表面覆盖物的方法,其包括:
将聚合物粘合剂和包含金刚石的耐磨颗粒混合,形成耐磨组合物;
由所述耐磨组合物形成涂料组合物;和
将所述薄膜施加到基层上;
其中,所述薄膜是通过将所述耐磨组合物挤压或压延到所述薄膜中的至少一种来形成的。
21.根据权利要求20所述的方法,其中所述薄膜是由叠压或滚动层压机施加至该基层。
22.根据权利要求20所述的方法,其中所述薄膜是由压延所述耐磨组合物而形成,且所述薄膜的厚度在约1mil至40mils范围内。
23.根据权利要求20所述的方法,其中所述薄膜是由在约160℃至约200℃的温度下将所述耐磨组合物压延而形成,所述耐磨组合物的聚合物粘合剂包含聚甲醛树脂。
24.根据权利要求20所述的方法,还包括在所述基层和所述耐磨层之间施加印刷层。
25.根据权利要求20所述的方法,其进一步包含在所述薄膜上形成顶涂层。
26.根据权利要求20所述的方法,其中所述顶涂层由施加顶涂层组合物形成,所述顶涂层组合物包含可固化聚合物组合物并通过UV辐射或电子束辐射中至少一种来固化所述顶涂层组合物。
27.根据权利要求20所述的方法,其中所述金刚石颗粒的平均粒径为约0.1nm至约1000nm。
28.根据权利要求20所述的方法,其中所述金刚石颗粒具有约0.1μm到约75μm的平均粒径。
29.根据权利要求20所述的方法,其中所述金刚石颗粒以总耐磨组合物重量的约1%至约50%的量存在。
30.根据权利要求20所述的方法,其中使用超过一种尺寸的金刚石耐磨添加剂。
31.根据权利要求20所述的方法,其中所述耐磨添加剂中包括纳米尺寸和微米尺寸的金刚石组合。
32.根据权利要求20所述的方法,其中所述金刚石颗粒,其中所述耐磨添加剂是金刚石和非金刚石材料的组合。
33.一种包括层压板结构的表面覆盖物,其包括:
具有与下表面相对的上表面的基层;
耐磨层,位于所述基层上,所述耐磨层包括聚合物粘合剂,所述聚合物粘合剂包括聚氨酯热熔树脂和耐磨添加剂,所述耐磨添加剂包括金刚石颗粒;和
可选择地在所述耐磨层上的顶涂层,所述顶涂层为连续层并且基本上不含所述耐磨颗粒。
34.根据权利要求1所述的耐磨热熔涂料组合物,其中所述热熔涂料组合物是包含PVC聚合物的透明涂料。
35.根据权利要求1所述的耐磨热熔涂料组合物,其中使用多种尺寸的金刚石耐磨添加剂。
36.根据权利要求1所述的耐磨热熔涂料组合物,其中,所述耐磨添加剂中包括纳米尺寸和微米尺寸的金刚石组合。
37.根据权利要求1所述的耐磨热熔涂料组合物,其中所述耐磨添加剂是金刚石和非金刚石材料的组合。
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PCT/US2017/055047 WO2018067641A1 (en) | 2016-10-05 | 2017-10-04 | Surface covering with wear layer having dispersed therein wear-resistant additives and method of making the same |
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CN114901482A (zh) * | 2019-12-12 | 2022-08-12 | 塔吉特Gdl公司 | 装饰性地板覆盖物生产方法 |
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EP3686028B1 (de) | 2019-01-22 | 2021-02-17 | Flooring Technologies Ltd. | Verfahren zur herstellung einer abriebfesten holzwerkstoffplatte |
ES2916708T3 (es) * | 2019-01-23 | 2022-07-05 | Flooring Technologies Ltd | Procedimiento para la fabricación de un panel multicapa resistente a la abrasión y al agua |
ES2917414T3 (es) * | 2019-03-01 | 2022-07-08 | Flooring Technologies Ltd | Procedimiento para la fabricación de un panel multicapa con una estructura superficial con una estructura superficial y panel fabricado con este procedimiento |
US20220314586A1 (en) * | 2021-03-31 | 2022-10-06 | Welspun Flooring Limited | High gloss polymer flooring tiles |
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AU2022204073A1 (en) | 2022-06-30 |
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