Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
  • D06N7/0028—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by colour effects, e.g. craquelé, reducing gloss
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
  • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
  • D06N7/0052—Compounding ingredients, e.g. rigid elements
  • D06N7/0055—Particulate material such as cork, rubber particles, reclaimed resin particles, magnetic particles, metal particles, glass beads

Definitions

• the present invention relates to decorative inlaid sheet materials and the like. More particularly the invention is concerned with the use of polyvinyl chloride (hereinafter "PVC") polymerization agglomerates as decorative particles and their application on floor and wall covering substrates to produce realistic inlaid patterns, utilizing heretofore unobtainable design strategies and exhibiting superior properties.
• PVC polyvinyl chloride
• Resilient inlaids are usually made by embedding ground plastic particulate material in a plastisol coating.
• United States Patent 4, 212,691 exemplifies such products and methods for their manufacture.
• the thickness of the particles of the decorative chips or flakes is stated to be from about 3 mils to about 25 mils (eg. see column 7, lines 62-64).
• the products disclosed all contain embedded chips or flakes ground from plastic sheet stock, even when chips or flakes from other stock materials are added (eg. see column 8, lines 4 et seq). These chips or flakes characteristically have a high aspect ratio (ie. length/thickness).
• a decorative, inlaid floor or wall covering which comprises: a) a substrate, b) a printed layer, generally comprising a printable substrate coating or sealant, onto which is printed a pattern in an ink suitable for floor or wall covering applications, applied over and in contact with said substrate, and c) an adhesive matrix, overlaying said printed layer, and in contact therewith, in which are embedded the resinous particles, said matrix being sufficiently transparent or transluscent to permit the underprint to show through.
• One of the advantages of this invention is that it employs ingredients and processing technology well known to those skilled in the art. Also, by employing a fluid plastisol as the matrix material binding the particles together, the product can be manufactured without the need for the high pressures or temperatures characteristic of the calendering or agglomeration steps of the prior art processes. This processing characteristic also distinguishes the subject process from those of the prior art which employ only dry blend resins, which are agglomerated through heat sintering.
• synethetic resins such as polystyrene, substituted polystyrene, preferably wherein the substituents are selected from the group consisting of alkyl (C 1 -C 10 , preferably C 1 -C 4 ), aryl (preferably, C 6 -C 14 ) , polyolefins such as polyethylene and polypropylene, acrylates and methacrylates, polyamides, polyesters, and any other natural or synethetic resin capable of being applied to the substrate or base coatings of this invention to provide a smooth and uniform surface and/or to improve the print quality of the substrate or base coating surface, are also applicable; provided such resin is otherwise compatible with the overall product composition and, therefor, within the principles of this invention.
• plasticizers which can be used are dibutyl sebacate, butyl benzyl sebacate, dibenzyl sebacate, dioctyl adipate, didecyl adipate, dibutyl phthlate, dioctyl phthlate, dibutoxy ethyl phthlate, butyl benzyl phthlate, dibenzyl phthlate, di (2-ethylhexyl) phthlate, alkyl or aryl modified phthalate esters, alkyl, aryl, or alkylaryl hydrocarbons, tricresyl phosphate, octyl diphenyl phosphate, dipropylene glycol dibenzoate, dibasic acid glycol esters, and the like.
• Printing onto the substrate can be effected by rotogravure, flexigraphic, screen printing, or other printing techniques conventionally employed in making floor ⁇ r wall covering products.
• the particles employed in this invention can have a wide variety of geometric shapes, provided that the aspect ratios of such particles fall within the ranges discussed herein.
• Exemplary of other geometric shapes are squares, triangles, circles, annuli, other polygons, etc, or irregular sizes and shapes, or a mixture of any or all of such shapes, including spheroidal.
• the optional overcoat or wearlayer is preferably a plastisol of the same or similar type as that discussed above in connection with the resins employed in the substrate coat and the adhesive layer or matrix.
• the formulations generally include materials to enhance special specific properties, for example gloss, wear, stain resistance, and scuff resistance.
• PVC extender k value 60 30
• TXIB Texanol isobutyrate
• the pearls produced were essentially spherical, dry and free running; did not exceed 0.60 inch in diameter, and had a particle size distribution range of .004 to .040.
• Examples 1 and 2 demonstrate decorative, inlaid floor coverings which constitute highly preferred embodiments of this invention and which comprise:
• a print layer of one or more inks made from effective amounts of a formulation comprising:
• a solvent preferably consisting essentially of methyl ethyl ketone and xylene
• PVC dispersion preferably having a relative viscosity about 2.5
• PVC extender preferably having a k value about 60
• plasticizer preferably butyl benzyl phthalate

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Laminated Bodies (AREA)
• Finishing Walls (AREA)
• Paints Or Removers (AREA)

Applications Claiming Priority (3)

Publications (3)

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Family Applications (1)

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Citations (3)

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• 1986
  • 1986-09-05 IE IE237786A patent/IE76461B1/en not_active IP Right Cessation
  • 1986-09-05 ES ES8601679A patent/ES2002286A6/es not_active Expired
  • 1986-09-08 CA CA000517656A patent/CA1283815C/fr not_active Expired - Lifetime
  • 1986-09-09 AT AT86906054T patent/ATE147680T1/de active
  • 1986-09-09 EP EP86906054A patent/EP0236478B1/fr not_active Expired - Lifetime
  • 1986-09-09 AU AU64068/86A patent/AU6406886A/en not_active Abandoned
  • 1986-09-09 DE DE3650594T patent/DE3650594T2/de not_active Expired - Fee Related
  • 1986-09-09 PT PT83337A patent/PT83337B/pt not_active IP Right Cessation
  • 1986-09-09 CN CN86106829.7A patent/CN1018622B/zh not_active Expired
  • 1986-09-09 WO PCT/US1986/001849 patent/WO1987001334A1/fr active IP Right Grant

Patent Citations (3)

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