US20160102428A1

US20160102428A1 - Aesthetically pleasing linoleum based surface coverings

Info

Publication number: US20160102428A1
Application number: US14/714,319
Authority: US
Inventors: Juergen Behrens; Jens Ehlers
Original assignee: Armstrong Flooring Inc
Current assignee: AFI Licensing LLC
Priority date: 2014-10-10
Filing date: 2015-05-17
Publication date: 2016-04-14
Also published as: EP3204228A1; AU2015328712A1; WO2016057080A1; CN107107552A

Abstract

Described herein are surface coverings comprising a carrier, a first linoleum composition, and a second linoleum composition; wherein the flow rate of the first linoleum composition is greater than the flow rate of the second linoleum composition.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/062,510 filed on Oct. 10, 2014. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to surface coverings having improved dimensional stability and aesthetics.

BACKGROUND

Surface coverings are used in a variety of applications to create aesthetically pleasing and structurally sound room environments. Among these surface coverings exist linoleum based surface coverings, which often suffer from poor dimensional stability and unacceptable aesthetics.
Thus, there is a need for linoleum based surface coverings that provide a combination of dimensional stability and acceptable aesthetics. Embodiments of the present invention are directed to meeting these needs.

SUMMARY

In some embodiments, the present invention provides a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; wherein the V_maxof the first linoleum composition is from about 300 cmm/s to about 1000 cmm/s; and wherein the V_maxof the second linoleum composition is less than 200 cmm/s.
Other embodiments provide a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and from about 25 wt. % to about 35 wt. % of a first inorganic filler; and a second linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; and wherein the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is from about 8:1 to about 15:1.
Yet other embodiments provide a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands comprising from about 20 voids/cm²to about 30 voids/cm²; and wherein the first inorganic filler comprises particles having an average particle size of from about 0.5 μm to about 20 μm.
In some embodiments, the present invention provides methods of improving the aesthetics of a linoleum based surface covering.

DETAILED DESCRIPTION

As used herein, the term “show through” refers to the perceivability of a carrier, visually and/or tactilely, from the top surface of a surface covering.
In some embodiments, the present invention provides a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; wherein the V_maxof the first linoleum composition is from about 300 cmm/s to about 1000 cmm/s; and wherein the V_maxof the second linoleum composition is less than 200 cmm/s.
In some embodiments, the surface coverings of the present invention comprise a linoleum core. In some embodiments, the linoleum core comprises a first linoleum layer and a second linoleum layer. In some embodiments, the first linoleum layer comprises a first linoleum composition. In some embodiments, the second linoleum layer comprises a second linoleum composition. In some embodiments, the first linoleum layer comprises a first linoleum composition; and the second linoleum layer comprises a second linoleum composition.
Other embodiments provide a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and from about 25 wt. % to about 35 wt. % of a first inorganic filler; and a second linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; and wherein the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is from about 8:1 to about 15:1.
Yet other embodiments provide a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands comprising from about 20 voids/cm²to about 30 voids/cm²; and wherein the first inorganic filler comprises particles having an average particle size of from about 0.5 μm to about 20 μm.
Some embodiments provide that the overall thickness of the surface covering may be varied, e.g. 2 mm being used for lighter wear applications and greater thicknesses such as 2.5 mm and 3.2 mm being used for more durable applications. However, in general, some embodiments provide that the surface covering can have an overall thickness of from 1 mm to 6 mm; alternatively from 1.5 mm to 4 mm. In some embodiments, the surface covering may be used as a linoleum floor covering and have a total thickness of about 1 mm to about 6 mm; alternatively from about 2 mm to about 4 mm.
In some embodiments, the carrier enhances mechanical integrity by acting as a backbone to the overall surface covering. The carrier may have a first side and a second side—the first side facing toward a subfloor and the second side facing towards a building space or room environment.
In some embodiments, the carrier may include a binder and a fibrous material. In some embodiments, the fibrous material is woven or knitted. In some embodiments, the binder may be present in an amount ranging from about 0 wt. % to about 40 wt. %, based on the weight of the carrier. In other embodiments, the binder may be present in an amount ranging from about 1 wt. % to about 30 wt. % based on the weight of the carrier.
According to some embodiments, the fibrous material may be selected from synthetic fiber, a cellulosic fiber, a natural fiber, a synthetic fabric, and a combination of two or more thereof.
In some embodiments, the synthetic fiber may be selected from a polyester (e.g. polyethylene terepthalate), a polyolefin (e.g. polypropylene), polytetrafluoroethylene, polyacrlyonitrile, a polyamide (e.g. nylon), polyacrylate, fiberglass, etc., and a combination of two or more thereof. In some embodiments, the cellulosic fiber and natural fiber may be selected from cotton, jute, viscose, kraft paper, rayon, sisal, and a combination of two or more thereof. Some embodiments provide that the carrier may comprise a material selected from: jute fabric; a mixed fabric of natural fibers; carbon fibers; aramid fibers; quartz fibers; alumina fibers; silicon carbide fibers; and a combination of two or more thereof.
In some embodiments, the binder may comprise a thermoplastic resin or a thermoset resin that is selected from, epoxies, polyurethanes, acrylic latex, phenolic resin, polyvinyl alcohol, carbohydrate polymers (i.e. starch), a cellulosic resin, a polyacrylamide, urea-formaldehyde, a melamine resin (e.g. melamine-formaldehyde, melamine-phenol-formaldehyde copolymer), an acrylic copolymer, styrene butadiene rubber, and a combination of two or more thereof. In some embodiments the binders may include one or more resins derived from the following monomers vinyl acetate, vinyl propionate, vinyl butyrate, vinyl chloride, vinylidine chloride, vinyl fluoride, vinylidene fluoride, ethyl acrylate, methyl acrylate, propyl acrylate, butyl acrylate, ethyl methacrylate, methyl methacrylate, butyl methacrylate, hydroxyethyl methylacrylate, styrene, butadiene, urethane, epoxy, melamine, and an ester.
In some embodiments, the carrier comprises polyethylene terephthalate. In some embodiments, the carrier comprises polyethylene terephthalate and fiberglass.
Some embodiments provide that the carrier is more or less an open structure and/or substantially porous material so as to facilitate penetration of the first linoleum composition through the carrier. In some embodiments, the carrier may be provided with an adhesive coating (i.e. adhesion promoter). In some embodiments, the adhesive coating comprises a natural drying oil (e.g. linseed oil or soya oil) or a synthetic material (e.g. acrylic, styrene butadiene rubber or similar) in order to enhance bonding of the first linoleum composition to the carrier.
In some embodiments, the carrier comprises a matrix. Some embodiments provide that the matrix is comprised of first strands and second strands, wherein each of the first and second strands are made of a fibrous material. In some embodiments, the first strands comprise a plurality of micro-strands that are oriented parallel to one another and face a first direction. In other embodiments, the second strands comprise a plurality of micro-strands that are oriented parallel to one another and face a second direction. In some embodiments, the first and the second direction may be offset by angle ranging from about 10° to about 90°. According to some embodiments, the angle offset between the first strands and the second strands create an intersecting grid of first stands and second stands. In some embodiments, the carrier comprises first, second, third, fourth, fifth, sixth, etc., strands—each of which may be oriented by an offset angle.
In some embodiments, the first strands may be separated from one another by a first distance—i.e. “length.” In another embodiment, the second strands may be separated from one another by a second distance—i.e. “width.” In some embodiments, the length may range from about 0.1 mm to about 5 mm. In some embodiments, the length may range from about 0.5 mm to about 2 mm. In some embodiments, the length may be about 1 mm. In some embodiments, the width may range from about 0.1 mm to about 5 mm. In some embodiments, the width may range from about 0.5 mm to about 2 mm. In some embodiments, the width may be about 1 mm. According to some embodiments the space between adjacent first strands and space between adjacent second strands creates voids in the carrier. In some embodiments, the dimensions of each void are directly related to the length and width between respective first and second adjacent strands, as well as the offset angle of intersecting first and second strands.
In some embodiments, the first strands are separated by a length of about 1 mm, the second strands are separated by a width of about 1 mm, and the first and second strands have an offset angle of about 90°—thereby resulting in substantially square voids having a length and a width of about 1 mm. According to other embodiments, the voids may be a variety of shapes, including triangular, rectangular, rhombus, trapezoidal, and polygonal, depending on the offset angle, the length, and the width.
In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises greater than about 10 voids/cm², across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises less than about 100 voids/cm², across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises from about 10 voids/cm²to about 100 voids/cm²across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises from about 15 voids/cm²to about 50 voids/cm²across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises from about 20 voids/cm²to about 30 voids/cm²across the surface of the carrier. In some embodiments, the offset angle, width, and length are selected such that the resulting carrier comprises about 25 voids/cm²across the surface of the carrier.
In some embodiments, the first and second strands may be oriented so that the voids extend all the way through the body of the carrier—i.e. from the first side of the carrier to the second side of the carrier. In other embodiments, the first and second strands may be oriented so that the voids only extend into the interior of the carrier from the first side or the second side. In some embodiments, the voids have a depth ranging from about 0.1 mm to about 0.5 mm; alternatively a depth of about 0.25 mm—when measured from the first or second side of the carrier into the body of the carrier.
In some embodiments, the first linoleum composition comprises: linoleum cement, a first organic filler, and a first inorganic filler. According to some embodiments, the first linoleum composition has a viscosity that is less than the viscosity of the second linoleum composition when measured under the same testing conditions (e.g. temperature). In some embodiments, the viscosity of the first and second linoleum compositions is measured by flow rate. In some embodiments, flow rate is represented by V_max. In some embodiments, the first linoleum composition has a flow rate (V_max) that is greater than the flow rate of the second linoleum composition when both flow rates are measured under the same testing conditions (e.g. temperature, pressure). The V_maxvalues reported herein represent the flow rates for the first and second linoleum compositions prior to calendaring, i.e. as a fresh mixmass after 30 minutes settling time.
V_maxis measured using a Rubber Capillary Rheometer (Goettfert model RCR). In some embodiments, the temperature of the RCR cylinder is about 90° C. The pressure in the RCR cylinder is about 160 bar, and the cylinder nozzle has a diameter of about 1.6 mm.
In some embodiments, the first linoleum composition comprises a first linoleum layer. In some embodiments, the thickness of the first linoleum layer may be varied and ranges from about 0.1 mm to about 5 mm; alternatively about 0.2 mm to about 4 mm; alternatively from about 0.5 mm to about 3 mm; about 0.75 mm to about 2 mm; alternatively about 1 mm.
In some embodiments, the first linoleum composition comprises: linoleum cement, a first organic filler, and a first inorganic filler. In some embodiments, the first linoleum composition comprises from about 30 wt. % to about 45 wt. % of linoleum cement, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 40 wt. % of linoleum cement, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 41 wt. % of linoleum cement, based on the total weight of the first linoleum composition.
The linoleum cement acts as a binder and comprises a drying oil and a resin, such as rosin, to act as a tackifier. In some embodiments, the drying oil comprises a fully or partially esterified fatty acid. In some embodiments, the drying oil comprises a polyunsaturated oil. In some embodiments, the drying oil comprises a dimer, a trimer or an oligomer obtained by reacting di, tri, and tetra-functional polyol compounds—such as glycerol or polyethylene glycol—with fatty acid compounds—such as palmitic acid, stearic acid, oleic acid, linoleic acid, pinolenic acid. In some embodiments, these drying oils include linseed oil, tall oil, soya oil, palm oil, castor oil, tung oil, olive oil, corn oil, canola oil, sunflower oil, peanut oil, camelina oil, lesquerella oil, vernonia oil, cardanol oil, coconut oil, karanja oil, jatropha oil, and a combination of two or more thereof. In some embodiments, the drying oil can be oxidized by atmospheric oxygen to form a dry solid. In some embodiments, the drying oil comprises linseed oil. In some embodiments, linseed oil is capable of drying faster than other oils.
In some embodiments the resin may be selected from gums and rosin. In some embodiments the linoleum cement may comprise from about 15 wt. % to about 35 wt. % of a resin based on the total weight of the total weight of the linoleum cement.
In some embodiments, the first linoleum composition comprises from about 20 wt. % to about 40 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 20 wt. % to about 35 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 25 wt. % to about 35 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 25 wt. % to about 30 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises about 28 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition.
Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 0.5 μm to about 20 μm. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 μm to about 10 μm. Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 μm to about 5 μm. In some embodiments, the particle size of the inorganic filler is selected to ensure a particular flow rate (e.g. V_max).
Some embodiments provide that the first and/or second inorganic filler may comprise limestone (calcium carbonate), kaolin clay, silica, vermiculite, ball clay or bentonite, talc, mica, gypsum, perlite, titanium dioxide, sand, barium sulfate, dolomite, wollastonite, calcite, pigments, zinc sulfate, or a combination of two or more thereof.
In some embodiments, the first linoleum composition comprises from about 15 wt. % to about 30 wt. % of a first organic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 18 wt. % to about 23 wt. % of the first organic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises about 22 wt. % of the first organic filler, based on the total weight of the first linoleum composition.
Some embodiments provide that the first and/or second organic filler comprises a cellulosic, a polymeric material, a non-polymeric material, or a combination of two or more thereof. In some embodiments, the first and/or second organic filler may be a fibrous material or a particulate material. In some embodiments, the first and/or second organic filler comprises a cellulosic material selected from wood fibers, cork, wood shavings, wood flour, paper fibers, cotton linters, a combination of two or more thereof.
In some embodiments the wood flour may be made from a hardwood or a softwood. In some embodiments, the wood flour comprises particles having a particle size distribution as follows: <160 μm: 40-90%, and <80 μm 10-50%. In other embodiments, the wood flour comprises particles having a particle size distribution as follows: <160 μm 50-85%; and <80 μm 10-30%.
In some embodiments, the polymeric material may include polyolefin, and the non-polymeric material may include a hydrophobic material. In some embodiments, the hydrophobic material has a melting point below 100° C. In some embodiments, the non-polymeric material is selected from Montan wax; Carnauba wax; bee wax; paraffin; and a combination of two or more thereof.
In some embodiments, the non-polymeric material may be present in an amount ranging from about 0.1 wt. % to about 1 wt. % based on the total weight of the first and/or second linoleum composition. In some embodiments, the non-polymeric material may be present in an amount ranging from about 0.1 wt. % to about 0.6 wt. % based on the total weight of the first and/or second linoleum composition.
In some embodiments, the first and/or second linoleum composition may further comprise a flame retardant, such as aluminum trihydrate, ammonium phosphate or dipentaerythritol; a flame retardants which form a barrier layer, such as borates and aluminum polyphosphates; a solid inorganic flame retardant, and a flame retardant which forms an insulating layer; an intumescence agent, or a combination of two or more thereof. In some embodiments, halogenated organic compounds, such as chlorinated paraffin, or halogenated organic phosphorus compounds may be used as an additional flame retardant.
In some embodiments, solid inorganic flame retardants are understood to include, for example, inorganic compounds, such as aluminum oxide hydrates, borates, e.g., zinc borates, ammonium phosphate, antimony oxides, aluminum hydroxides, preferably aluminum trihydroxide, and magnesium hydroxide, aluminum hydroxide and magnesium hydroxide also being referred to as water-releasing flame retardants.
In some embodiments, the first and/or second linoleum composition further comprises a dispersant, a flocculant, a defoaming agent, a fungicide, a biocide, or a combination thereof. In some embodiments, the first and/or second linoleum composition further comprises a metal oxide, a metal hydroxide, or a combination thereof. In some embodiments, the metal oxide comprises zinc oxide.
In some embodiments, the second linoleum composition comprises linoleum cement, a second organic filler, and a second inorganic filler. According to some embodiments, the second linoleum composition has a viscosity that is greater than the viscosity of the first linoleum composition when measured under the same testing conditions (e.g. temperature).
In some embodiments, the V_maxof the first linoleum composition is from about 300 cmm/s to about 1000 cmm/s. In some embodiments, the V_maxof the first linoleum composition is from about 500 cmm/s to about 900 cmm/s. In some embodiments, the V_maxof the first linoleum composition is from about 600 cmm/s to about 800 cmm/s. In some embodiments, the V_maxof the first linoleum composition is from about 650 cmm/s to about 750 cmm/s. In some embodiments, the V_maxof the first linoleum composition is about 730 cmm/s.
In some embodiments, the V_maxof the second linoleum composition is from about 30 cmm/s to about 200 cmm/s. In other embodiments, the V_maxof the second linoleum composition is from about 40 cmm/s to about 100 cmm/s. In further embodiments, the V_maxof the second linoleum composition is from about 50 cmm/s to about 100 cmm/s. In some embodiments, the V_maxof the second linoleum composition is less than about 200 cmm/s. In some embodiments, the V_maxof the second linoleum composition is less than about 100 cmm/s. In some embodiments, the V_maxof the second linoleum composition is from about 10 cmm/s to about 100 cmm/s. In some embodiments, the V_maxof the second linoleum composition is less than about 75 cmm/s. In some embodiments, the V_maxof the second linoleum composition is about 60 cmm/s.
In some embodiments, the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is from about 5:1 to about 20:1. In some embodiments, the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is from about 5:1 to about 15:1. In some embodiments, the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is from about 8:1 to about 15:1. In some embodiments, the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is from about 8:1 to about 12:1. In some embodiments, the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) is about 12:1.
In some embodiments, the first linoleum composition forms a first linoleum layer. In some embodiments, the first linoleum layer has a thickness of from about 0.5 mm to about 5 mm; alternatively from about 0.75 mm to about 3 mm; alternatively from about 0.9 mm to about 1.1 mm.
In some embodiments, the second linoleum composition forms a second linoleum layer. In some embodiments, the second linoleum layer has a thickness of from about 0.5 mm to about 5 mm; alternatively from about 0.75 mm to about 3 mm; alternatively from about 1 mm to about 1.5 mm; alternatively from about 1.1 mm to about 1.4 mm.
In some embodiments, the second linoleum composition comprises from about 17.5 wt. % to about 70 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 25 wt. % to about 45 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 30 wt. % to about 40 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 36 wt. % of linoleum cement, based on the total weight of the second linoleum composition.
In some embodiments, the second linoleum composition comprises from about 10 wt. % to about 20 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 12 wt. % to about 18 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 14 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition.
In some embodiments, the second linoleum composition comprises from about 30 wt. % to about 45 wt. % of a second organic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 36 wt. % to about 41 wt. % of the second organic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 39 wt. % of the second organic filler, based on the total weight of the second linoleum composition.
In some embodiments, the second linoleum composition comprises from about 30 wt. % to about 45 wt. % of wood flour, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 36 wt. % to about 41 wt. % of wood flour, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 39 wt. % of wood flour, based on the total weight of the second linoleum composition.
Previous attempts to manufacture flooring surfaces comprising linoleum cement and filler have been problematic in that the flooring surfaces exhibit unacceptable aesthetics. It has been discovered that positioning a first linoleum composition adjacent to a carrier, wherein the first linoleum composition has a low viscosity and high flow rate results in a surface covering that exhibits superior aesthetics.
In some embodiments, the use of a first linoleum composition that has low viscosity/high flow rate, allows the first linoleum composition to better penetrate the voids present in the carrier. In some embodiments, the penetration is sufficient for the carrier to be embedded in the first linoleum composition. According to some embodiments, greater penetration increases the amount of surface contact between the first linoleum composition and the carrier. While choosing not to be bound by theory, the present inventors believe that increased surface contact enhances the mechanical adhesion and leveling between the first linoleum composition and the carrier and decreases the amount of “show-through” on the surface covering. In addition, greater mechanical adhesion between the first linoleum composition and the carrier is believed to enhance the structural integrity of the overall surface covering. Decreased show-through enhances the overall aesthetic appearance as the intersecting grid of the carrier is both less visually and tactilely apparent on the final surface covering.
In some embodiments, the overall volume of the carrier is V_T, as measured by the surface area of the first side or the second side of the carrier and multiplied by the distance that spans from the first side to the second side through the carrier. V_Tincludes the volume occupied by both strands and voids. The volume of the strands V_Sis the volume occupied by the strands within the carrier, as calculated by measuring the weight of strands used in a single carrier and dividing it by the density of the strand. Thus, the volume of the voids V_Vmay be calculated by the following equation:
V _V =V _T −V _S
In some embodiments, when the first linoleum composition is applied to the carrier and penetrates the voids of the carrier, at least some of the void volume V_Vwill be occupied by the first linoleum composition V_L. Thus, the amount of penetration by the first linoleum composition into the carrier voids—i.e. “saturation percentage”—can be quantified by dividing the volume of the first linoleum composition (V_L) by the void volume (V_V) and is represented by the following equation:
Saturation %=V _L /V _V
In some embodiments, greater than 50% of the voids in the carrier are saturated with the first linoleum composition. In other embodiments, greater than 55% of the voids in the carrier are saturated with the first linoleum composition. In further embodiments, greater than 60% of the voids in the carrier are saturated with the first linoleum composition. In still further embodiments, greater than 65% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 70% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 75% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 80% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 85% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 90% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 95% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 97.5% of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 99% of the voids in the carrier are saturated with the first linoleum composition. Without being bound by theory, it is believed that greater saturation also leads to superior mechanical adhesion between the carrier and the first linoleum composition and reduces the amount of show-through of the carrier in the first linoleum composition—thereby providing superior aesthetics and performance to the surface covering.
In some embodiments, the surface covering may further comprise a coating. In some embodiments, the coating is applied to the second linoleum composition. In some embodiments, the coating may perform as a wear layer. In some embodiments, the coating is UV curable, moisture curable or thermally curable. In some embodiments, the coating may be transparent and cured by UV radiation. In some embodiments, the coating provides good scratch and abrasion resistance and is sufficiently transparent to allow a print design to be visible from and through the topside of the product. In some embodiments, the coating comprises a UV curable polyurethane. In some embodiments, the coating comprises a moisture curable polyurethane. In some embodiments, the coating comprises an acrylate. In some embodiments, the coating comprises a polyurethane and an acrylate.
In some embodiments, the coating may comprise particles that enhance dimensional stability and/or scratch resistance. In some embodiments, the particles are selected from chalk, barium sulfate, slate powder, silica, kaolin, quartz powder, talc, lignin, powdered glass, aluminum oxide, and glass fibers.
In some embodiments, the coating may have a thickness of from about 0.001 mm to 1 mm. In some embodiments, the coating may have a thickness of from about 0.005 mm to 0.5 mm. In some embodiments, the coating may have a thickness of from about 0.0075 mm to about 0.25 mm. In some embodiments, the coating may have a thickness of about 0.01 mm.
In some embodiments, the surface covering of the present invention may be made according to the following process. The first linoleum composition is produced by mixing the all components, such as the first linoleum cement, the first organic filler, and the first inorganic filler in a suitable mixing apparatus—e.g. a kneader, roll mill, or extruder, to form as homogenous a matrix as possible (mixed mass), In some embodiments, the first linoleum composition may further contain conventional additives, such as processing aids, antioxidants, UV stabilizers, slip agents and the like, which are selected as a function of the binder.
According to some embodiments, the homogenous matrix of the first linoleum composition is then fed into a roll mill (e.g., a calendar) and pressed onto a carrier typically at a temperature of typically 10° C. to 150° C. In some embodiments, the roll mill may be adjusted such that the resulting first linoleum composition/carrier combination has the desired layer thickness.
According to some embodiments, the second linoleum composition is produced separately and rolled into sheets and granulated. In some embodiments, the granulates are then mixed together and fed into the roll mill (e.g. a calendar) to produce a linoleum sheet of the second linoleum composition. The second linoleum sheet can then be pressed either directly onto the carrier/first linoleum composition or rolled onto the carrier/first linoleum composition through a roll mill.
The invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes and are not intended to limit the invention in any manner.

EXAMPLES

Example 1

Described in Table 1 (below) are the compositions and flow rates of exemplary surface coverings of the present invention, along with the compositions and flow rates of comparative surface coverings.

TABLE 1

		Comp.	Comp.	Comp.
Ex. I	Ex. II	Ex. I	Ex. II	Ex. III

First Linoleum Composition
Thickness (mm)	0.9	1.1	0.9	1.1	0.9

Ingredients	Wt. %

Linoleum cement	41	41	43	40	35
Wood flour	22	22	23	31	8
Limestone	28	28	16	20	24
ATH	9	9	1	9	9
Scrap	—	—	13	—	24
Pigments/Fibers	—	—	3	—	—
V_max(cmm/second)	730	730	400	820	1560
Second Linoleum
Composition
Thickness (mm)	1.1	1.4	1.1	1.4	1.1

Ingredients	Wt. %

Linoleum cement	36	36	42	35	36
Wood flour	39	39	41	36	39
Limestone	14	14	10	18	12
ATH	9	9	1	9	9
Pigments	2	2	6	2	4
V_max(cmm/second)	60	60	250	680	100

Example 2

Table 2 (below) describes a comparison of the flow rates of the surface coverings described in Table 1 (above), and their respective abilities to prevent carrier show through. The show through results are based on visual inspection of the surface coverings from the exposed surface of the second linoleum layer.

TABLE 2

				Comp.
Ex. I	Ex. II	Comp. Ex. I	Comp. Ex. II	Ex. III

Show Through	No	No	Yes	Yes	n/a - Defects

The data described in Table 2 (above) demonstrates that exemplary surface coverings of the present invention prevent show through of the carrier, while comparative surface coverings do not.
As those skilled in the art will appreciate, numerous changes and modifications may be made to the embodiments described herein, without departing from the spirit of the invention. It is intended that all such variations fall within the scope of the invention.

Claims

1. A surface covering comprising:

a carrier comprising an intersecting grid of first strands and second strands;

a first linoleum composition having a first flow rate (V_max) that ranges from about 300 cmm/s to about 1000 cmm/s, the first linoleum composition comprising:

linoleum cement;

a first organic filler; and

a first inorganic filler; and

a second linoleum composition having a second flow rate (V_max) that is less than 200 cmm/s, the second linoleum composition adjacent to the first linoleum composition and comprising:

linoleum cement;

a second organic filler; and

a second inorganic filler; and

wherein the ratio of the first linoleum composition flow rate (V_max) to the second linoleum composition flow rate (V_max) ranges from about 5:1 to about 20:1.

2. The surface covering of claim 1, wherein the V_maxof the first linoleum composition is about 600 cmm/s to about 800 cmm/s.

3. The surface covering of claim 1 or claim 2, wherein the V_maxof the second linoleum composition is less than about 100 cmm/s.

4. The surface covering of claim 1, wherein the carrier is embedded in the first linoleum composition.

5. The surface covering of claim 1, wherein the first linoleum composition further comprises a metal oxide or a metal hydroxide, wherein the metal oxide comprises zinc oxide.

6. The surface covering of claim 1, wherein the first linoleum composition comprises from about 30 wt. % to about 45 wt. % of linoleum cement.

7. The surface covering of claim 1, wherein the first linoleum composition comprises from about 15 wt. % to about 30 wt. % of the first organic filler.

8. The surface covering of claim 1, wherein the first linoleum composition comprises from about 20 wt. % to about 40 wt. % of the first inorganic filler.

9. The surface covering of claim 1, wherein the intersecting grid comprises voids in an amount ranging from about 20 voids/cm2 to about 30 voids/cm2.

10. The surface covering of claim 9, wherein the voids have a length of from about 0.1 mm to about 5 mm, and a width of from about 0.1 mm to about 5 mm.

11. The surface covering of claim 9, wherein the voids have a depth of from about 0.1 mm to about 0.5 mm.

12. The surface covering of claim 9, wherein voids are at least 75% saturated with the first linoleum composition.

13. A surface covering comprising:

a carrier comprising an intersecting grid of first strands and second strands comprising from about 20 voids/cm²to about 30 voids/cm²;

a first linoleum composition having a first flow rate (V_max), the first linoleum composition adjacent to the carrier and comprising:

linoleum cement;

a first organic filler; and

a first inorganic filler in an amount ranging from about 25 wt. % to 35 wt. % based on the total weight of the first linoleum composition; and

a second linoleum composition having a second flow rate (V_max) comprising:

linoleum cement;

a second organic filler;

a second inorganic filler; and

wherein the first inorganic filler comprises particles having an average particle size of from about 0.5 μm to about 20 μm.

14. The surface covering of claim 13, wherein the V_maxof the first linoleum composition is about 500 cmm/s to about 900 cmm/s.

15. The surface covering of claim 13 or claim 14, wherein the V_maxof the second linoleum composition is from about 10 cmm/s to about 100 cmm/s.

16. The surface covering of claim 13, wherein the first linoleum composition further comprises a metal oxide or a metal hydroxide, wherein the metal oxide comprises zinc oxide.

17. The surface covering of claim 13, wherein the first linoleum composition comprises from about 30 wt. % to about 45 wt. % linoleum cement.

18. The surface covering of claim 13, wherein the first linoleum composition comprises from about 18 wt. % to about 23 wt. % of the first organic filler.

19. The surface covering of claim 13, wherein voids are at least 90% saturated with the first linoleum composition.

20. The surface covering of claim 13, wherein a ratio of the first flow rate (V_max) of the first linoleum composition to the second flow rate (V_max) of the second linoleum composition, ranges from about 8:1 to about 15:1.