U.S. patent application number 14/714319 was filed with the patent office on 2016-04-14 for aesthetically pleasing linoleum based surface coverings.
The applicant listed for this patent is ARMSTRONG WORLD INDUSTRIES, INC.. Invention is credited to Juergen Behrens, Jens Ehlers.
Application Number | 20160102428 14/714319 |
Document ID | / |
Family ID | 53277094 |
Filed Date | 2016-04-14 |
United States Patent
Application |
20160102428 |
Kind Code |
A1 |
Behrens; Juergen ; et
al. |
April 14, 2016 |
AESTHETICALLY PLEASING LINOLEUM BASED SURFACE COVERINGS
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.
Inventors: |
Behrens; Juergen;
(Harpstedt, DE) ; Ehlers; Jens; (Hamminkein,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ARMSTRONG WORLD INDUSTRIES, INC. |
Lancaster |
PA |
US |
|
|
Family ID: |
53277094 |
Appl. No.: |
14/714319 |
Filed: |
May 17, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62062510 |
Oct 10, 2014 |
|
|
|
Current U.S.
Class: |
442/74 |
Current CPC
Class: |
B32B 2307/734 20130101;
B32B 9/02 20130101; B32B 7/02 20130101; B32B 2264/00 20130101; B32B
2264/067 20130101; B32B 2471/00 20130101; D06N 2201/0263 20130101;
D06N 2211/12 20130101; D06N 1/00 20130101; B32B 9/04 20130101; B32B
9/045 20130101; D06N 2211/066 20130101; D06N 2201/0254 20130101;
B32B 2264/10 20130101; D06N 2201/082 20130101 |
International
Class: |
D06N 1/00 20060101
D06N001/00 |
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.sub.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.sub.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.sub.max) to the second
linoleum composition flow rate (V.sub.max) ranges from about 5:1 to
about 20:1.
2. The surface covering of claim 1, wherein the V.sub.max of 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.sub.max of 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/cm.sup.2 to about 30 voids/cm.sup.2; a first
linoleum composition having a first flow rate (V.sub.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.sub.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 .mu.m
to about 20 .mu.m.
14. The surface covering of claim 13, wherein the V.sub.max of 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.sub.max of 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.sub.max) of the first linoleum composition to the
second flow rate (V.sub.max) of the second linoleum composition,
ranges from about 8:1 to about 15:1.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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
[0002] The present disclosure relates to surface coverings having
improved dimensional stability and aesthetics.
BACKGROUND
[0003] 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.
[0004] 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
[0005] 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.sub.max of
the first linoleum composition is from about 300 cmm/s to about
1000 cmm/s; and wherein the V.sub.max of the second linoleum
composition is less than 200 cmm/s.
[0006] 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.sub.max) to the second linoleum composition flow rate
(V.sub.max) is from about 8:1 to about 15:1.
[0007] 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/cm.sup.2 to about 30 voids/cm.sup.2;
and wherein the first inorganic filler comprises particles having
an average particle size of from about 0.5 .mu.m to about 20
.mu.m.
[0008] In some embodiments, the present invention provides methods
of improving the aesthetics of a linoleum based surface
covering.
DETAILED DESCRIPTION
[0009] 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.
[0010] 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.sub.max of
the first linoleum composition is from about 300 cmm/s to about
1000 cmm/s; and wherein the V.sub.max of the second linoleum
composition is less than 200 cmm/s.
[0011] 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.
[0012] 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.sub.max) to the second linoleum composition flow rate
(V.sub.max) is from about 8:1 to about 15:1.
[0013] 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/cm.sup.2 to about 30 voids/cm.sup.2;
and wherein the first inorganic filler comprises particles having
an average particle size of from about 0.5 .mu.m to about 20
.mu.m.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] In some embodiments, the carrier comprises polyethylene
terephthalate. In some embodiments, the carrier comprises
polyethylene terephthalate and fiberglass.
[0021] 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.
[0022] 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.degree. to
about 90.degree.. 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.
[0023] 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.
[0024] 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.degree.--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.
[0025] In some embodiments, the offset angle, width, and length may
be selected such that the resulting carrier comprises greater than
about 10 voids/cm.sup.2, 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/cm.sup.2, 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/cm.sup.2 to about 100 voids/cm.sup.2 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 15 voids/cm.sup.2 to about 50 voids/cm.sup.2 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 20 voids/cm.sup.2 to about 30 voids/cm.sup.2
across 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/cm.sup.2 across the surface of the
carrier.
[0026] 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.
[0027] 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.sub.max.
In some embodiments, the first linoleum composition has a flow rate
(V.sub.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.sub.max
values 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.
[0028] V.sub.max is measured using a Rubber Capillary Rheometer
(Goettfert model RCR). In some embodiments, the temperature of the
RCR cylinder is about 90.degree. C. The pressure in the RCR
cylinder is about 160 bar, and the cylinder nozzle has a diameter
of about 1.6 mm.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] Some embodiments provide that the first inorganic filler
comprises particles having an average particle size of from about
0.5 .mu.m to about 20 .mu.m. Some embodiments provide that the
first inorganic filler comprises particles having an average
particle size of from about 1 .mu.m to about 10 .mu.m. Some
embodiments provide that the first inorganic filler comprises
particles having an average particle size of from about 1 .mu.m to
about 5 .mu.m. In some embodiments, the particle size of the
inorganic filler is selected to ensure a particular flow rate (e.g.
V.sub.max).
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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 .mu.m: 40-90%, and <80 .mu.m 10-50%. In other
embodiments, the wood flour comprises particles having a particle
size distribution as follows: <160 .mu.m 50-85%; and <80
.mu.m 10-30%.
[0039] 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.degree. 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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).
[0045] In some embodiments, the V.sub.max of the first linoleum
composition is from about 300 cmm/s to about 1000 cmm/s. In some
embodiments, the V.sub.max of the first linoleum composition is
from about 500 cmm/s to about 900 cmm/s. In some embodiments, the
V.sub.max of the first linoleum composition is from about 600 cmm/s
to about 800 cmm/s. In some embodiments, the V.sub.max of the first
linoleum composition is from about 650 cmm/s to about 750 cmm/s. In
some embodiments, the V.sub.max of the first linoleum composition
is about 730 cmm/s.
[0046] In some embodiments, the V.sub.max of the second linoleum
composition is from about 30 cmm/s to about 200 cmm/s. In other
embodiments, the V.sub.max of the second linoleum composition is
from about 40 cmm/s to about 100 cmm/s. In further embodiments, the
V.sub.max of the second linoleum composition is from about 50 cmm/s
to about 100 cmm/s. In some embodiments, the V.sub.max of the
second linoleum composition is less than about 200 cmm/s. In some
embodiments, the V.sub.max of the second linoleum composition is
less than about 100 cmm/s. In some embodiments, the V.sub.max of
the second linoleum composition is from about 10 cmm/s to about 100
cmm/s. In some embodiments, the V.sub.max of the second linoleum
composition is less than about 75 cmm/s. In some embodiments, the
V.sub.max of the second linoleum composition is about 60 cmm/s.
[0047] In some embodiments, the ratio of the first linoleum
composition flow rate (V.sub.max) to the second linoleum
composition flow rate (V.sub.max) is from about 5:1 to about 20:1.
In some embodiments, the ratio of the first linoleum composition
flow rate (V.sub.max) to the second linoleum composition flow rate
(V.sub.max) is from about 5:1 to about 15:1. In some embodiments,
the ratio of the first linoleum composition flow rate (V.sub.max)
to the second linoleum composition flow rate (V.sub.max) is from
about 8:1 to about 15:1. In some embodiments, the ratio of the
first linoleum composition flow rate (V.sub.max) to the second
linoleum composition flow rate (V.sub.max) is from about 8:1 to
about 12:1. In some embodiments, the ratio of the first linoleum
composition flow rate (V.sub.max) to the second linoleum
composition flow rate (V.sub.max) is about 12:1.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] In some embodiments, the overall volume of the carrier is
V.sub.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.sub.T includes the volume occupied by both strands and voids. The
volume of the strands V.sub.S is 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.sub.V may be calculated
by the following equation:
V.sub.V=V.sub.T-V.sub.S
[0057] 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.sub.V will be occupied by the first
linoleum composition V.sub.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.sub.L) by the void volume
(V.sub.V) and is represented by the following equation:
Saturation %=V.sub.L/V.sub.V
[0058] 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.degree. C. to 150.degree. C. In some embodiments, the
roll mill may be adjusted such that the resulting first linoleum
composition/carrier combination has the desired layer
thickness.
[0064] 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.
[0065] 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
[0066] 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-US-00001 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.sub.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.sub.max (cmm/second) 60 60 250 680 100
Example 2
[0067] 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-US-00002 TABLE 2 Comp. Ex. I Ex. II Comp. Ex. I Comp. Ex. II
Ex. III Show Through No No Yes Yes n/a - Defects
[0068] 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.
[0069] 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.
* * * * *