U.S. patent application number 15/096958 was filed with the patent office on 2016-11-17 for foamed surface covering with coherent layer.
The applicant listed for this patent is KITTRICH CORPORATION. Invention is credited to Mark A. Calkins.
Application Number | 20160332419 15/096958 |
Document ID | / |
Family ID | 50100226 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160332419 |
Kind Code |
A1 |
Calkins; Mark A. |
November 17, 2016 |
FOAMED SURFACE COVERING WITH COHERENT LAYER
Abstract
Embodiments of a new foamed surface covering are disclosed,
wherein a primary layer of polymeric foam features at least one
coherent layer consisting of a water-resistant blend of
styrene-maleic anhydride and acrylic resin. The coherent layer
facilitates the secured and reusable application of the surface
covering after repeated washings.
Inventors: |
Calkins; Mark A.; (San
Jacinto, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KITTRICH CORPORATION |
Pomona |
CA |
US |
|
|
Family ID: |
50100226 |
Appl. No.: |
15/096958 |
Filed: |
April 12, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13624813 |
Sep 21, 2012 |
9339994 |
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15096958 |
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61683655 |
Aug 15, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2266/0278 20130101;
B32B 3/30 20130101; B32B 5/18 20130101; B32B 2307/744 20130101;
B32B 5/026 20130101; B32B 5/245 20130101; B32B 27/065 20130101;
B32B 5/022 20130101; B32B 2266/0235 20130101; Y10T 428/249953
20150401; B32B 2264/104 20130101; B32B 27/302 20130101; B32B 3/263
20130101; B32B 27/18 20130101; B32B 27/308 20130101; Y10T 428/239
20150115; B32B 27/304 20130101; B32B 2471/04 20130101; B32B
2307/726 20130101; B32B 5/028 20130101; B32B 2471/00 20130101; B32B
2270/00 20130101; B32B 27/08 20130101; B32B 2262/0276 20130101;
B32B 7/06 20130101; Y10T 428/24504 20150115 |
International
Class: |
B32B 5/24 20060101
B32B005/24; B32B 3/26 20060101 B32B003/26; B32B 3/30 20060101
B32B003/30; B32B 27/18 20060101 B32B027/18; B32B 5/18 20060101
B32B005/18; B32B 7/06 20060101 B32B007/06; B32B 27/08 20060101
B32B027/08; B32B 27/30 20060101 B32B027/30; B32B 27/06 20060101
B32B027/06; B32B 5/02 20060101 B32B005/02 |
Claims
1. A surface covering comprising: a multilayered composite
material, wherein, the multilayered composite material further
comprises: (a) a primary layer of polymeric foam; and (b) at least
one layer of coherent resin.
2. The surface covering according to claim 1, wherein the primary
layer of polymeric foam further includes a polymeric compound
containing a resin selected from the group consisting of latex,
polyvinyl chloride, polyurethane and ethylene vinyl acetate.
3. The surface covering according to claim 1, wherein the primary
layer of polymeric foam is composed of a thermally cured polyvinyl
chloride (PVC) compound, the compound further comprising a
plasticizer, polyvinyl chloride resins, calcium carbonate, a
chemical foaming agent, a heat stabilizer, and a pigment.
4. The compound according to claim 3, wherein the plasticizer is
selected from the group consisting of Diisononyl phthalates (DINP),
Dioctyl terephthalates (DOTP), Epoxidized Soybean Oils (ESO), or
combinations thereof.
5. The compound according to claim 3, further comprising a
copolymeric blend of two dissimilar PVC homopolymer dispersion
resins.
6. The surface covering according to claim 1, wherein the primary
layer is between 1.275 mm to 6.35 mm in thickness.
7. The surface covering according to claim 1, wherein the primary
layer of polymeric foam encases an intermediate reinforcing layer
of knitted or nonwoven scrim.
8. The surface covering according to claim 7, wherein the knitted
scrim comprises woven yarns selected from the group consisting of
natural or synthetic yarns.
9. The surface covering according to claim 8, wherein the woven
construction of the knitted scrim defines a series of
apertures.
10. The surface covering according to claim 7, wherein the nonwoven
scrim comprises autogenously bonded polyester fibers.
11. The surface covering according to claim 1, wherein the primary
layer consists of a continuous layer of unsupported polymeric
foam.
12. The surface covering according to claim 11, wherein the
continuous layer of unsupported foam includes at least one surface
having a plurality of micro-embossed indentations.
13. The surface covering according to claim 12, wherein the
micro-embossed indentations provide an arrangement of concave
recesses to enhance the bonding characteristics of the coherent
layer.
14. The surface covering according to claim 1, wherein at least one
layer of coherent resin includes a composition of Styrene-Maleic
Anhydride copolymer and Acrylic resin.
15. The surface covering according to claim 1, wherein at least one
layer of coherent resin is between 0.5 mm to 1.5 mm in
thickness.
16. The surface covering according to claim 14, wherein the
Styrene-Maleic Anhydride copolymer has a glass transition (Tg)
temperature in the range of -30.degree. to -40.degree. C.
17. The surface covering according to claim 14, wherein the
Styrene-Maleic Anhydride copolymer is formed by means of controlled
radical polymerization.
18. The surface covering according to claim 14, wherein the
Styrene-Maleic Anhydride copolymer is water resistant.
19. The surface covering according to claim 14 wherein the coherent
layer of Styrene-Maleic Anhydride copolymer and Acrylic resin
impedes the migration of plasticizers.
20. The surface covering according to claim 14, wherein the
coherent layer of Styrene-Maleic Anhydride copolymer and Acrylic
resin prevents the adhesion of residual polymeric foam to subjacent
surfaces upon removal.
21-44. (canceled)
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 13/624,813, filed Sep. 21, 2012, which is based on and claims
priority to U.S. Provisional Patent Application 61/683,655, filed
Aug. 15, 2012, each of which is incorporated by reference as if
expressly set forth in their respective entirety herein.
FIELD OF THE INVENTION
[0002] The present invention is directed toward removable nonslip
foamed surface coverings which are used as rug underlay pads or,
alternatively, as shelf, drawer or storage liners. In particular,
the covering features an improved composite material having a
primary layer of polymeric foam combined to at least one coherent
layer consisting of a water-resistant blend of styrene-maleic
anhydride and acrylic resin. The structure of the multilayered
composite material facilitates the secured and reusable application
of the surface covering after repeated washings.
DESCRIPTION OF THE PRIOR ART
[0003] Nonslip foamed surface coverings have been extensively sold
at retail venues and are commonly utilized as rug underlay
materials or as shelf and drawer liners. One type of nonslip
covering consists of a knitted polyester scrim featuring a coating
of thermally foamed polyvinyl chloride (PVC) resin. The knitted
construction of the scrim provides an arrangement of woven yarns
defining a pattern of apertures that correspond to a configuration
of openings extending through the thickness of the cured PVC
material. Alternatively, the PVC resin may be knife coated to
either side of a knitted scrim devoid of openings, or to a
non-woven fabric of autogenously bonded fibers, producing a
continuous layer of supported foam. The PVC compound also includes
a plasticizer that imparts a removable nonslip mechanical bond
between the foamed covering and an applied surface. Although
thermally foamed nonslip coverings provide a layer of cushioning
and surface protection, such unanchored materials require frequent
repositioning because they are prone to bunch up or shift through
repetitive use.
[0004] Another problem with thermally foamed PVC coverings relates
to the migration of monomeric and polymeric plasticizers that have
been known to cause marring of certain types of underlying
surfaces. Such vulnerable surfaces include lacquered or oil-based
painted finishes, along with composite wood shelving and
furnishings embellished with dry thermal transfer appliques, which
simulate decorative wood grained facings and are made from acrylic
or nitrocellulose resins. Plasticizers within foamed PVC compounds
may also react negatively with vinyl flooring and wood laminates
coated with polyurethane varnishes. In addition, the application of
plasticizers within foamed PVC coverings--although useful in
providing nonslip properties to such materials--are also known to
adversely affect the performance of anchor coatings that are
formulated from conventional acrylic and rubber based
adhesives.
[0005] The primary disadvantage of the prior art, inherent within
foamed PVC coverings that feature self-adhesive anchor coatings,
concerns the inadvertent disintegration of the material upon
removal. For example, U.S. Pat. No. 5,120,587, issued on Jun. 9,
1992 to L. McDermott, III et al., discloses a support binder for
carpeting in the form of a scrim having a plurality of alternating
spaced frame elements sheathed within a thermally foamed coating of
polymeric resin. The foamed binder includes corresponding layers of
adhesive to secure carpets and area rugs onto floors or other
carpeting. Over time, the cellular structure of the polymeric foam
degrades with age, while the self-adhesive anchor coating becomes
fully cured to a selected surface. Consequently, replacement of the
self-adhesive covering will result in the residual adhesion of
miniscule fragments of foam to the underside of carpeting and to
subjacent flooring surfaces.
[0006] One remedy in the prior art includes the application of an
intermediate layer of polymeric film to act as a mechanical barrier
between the polymeric foam and the underlying coating of adhesive.
The polymeric film provides an increased surface area to enhance
the adhesion of the PVC covering and prevents the transfer of
residual foam to flooring or to the interiors of cabinets and
drawers. For instance, U.S. Pat. No. 7,601,653, issued on Oct. 13,
2009 to S. Price, discloses an adhesive grip liner comprising a
foam sheet material which is joined to a layer of vinyl film. The
underside of the vinyl is coated with a continuous or imprinted
layer of adhesive. Similarly, U.S. Patent Application Publication
US 2002/0145089 A1 by M. Calkins, published on Oct. 10, 2002,
discloses a protective covering sheet having a scrim-supported
foamed PVC working surface, which is adhered to a layer of
polymeric film. As in the previous related example, a pressure
sensitive adhesive is applied to the reverse face of the polymeric
film. In both embodiments, a removable release liner serves as a
protective masking to the layer of adhesive. Although the use of
release liners enable the efficient packaging of self-adhesive
foamed surface coverings, the dissimilar thicknesses of the
component layers that make up such materials create an unbalanced
laminated construction, thereby causing the inadvertent wrinkling
of the finished goods when they are wound into rolls for retail
distribution.
[0007] The systems, methods, and inventions described in the
above-identified patent publications are found lacking in
disclosing an improved reusable surface covering material, which is
comprised of a layer of polymeric foam combined to a
water-resistant layer of coherent resin.
[0008] Accordingly, it is a principal object of the present
invention to provide an improved multilayered composite material
for use as rug underlay pads, or shelf and storage liners, having a
resilient layer of polymeric foam combined to an anchor coating of
coherent resin that facilitates the secured and reusable
application of the surface covering after repeated washings.
[0009] It is a further object of the present invention to provide a
multilayered composite material having a layer of thermally cured
polymeric foam encasing an intermediate reinforcing layer of
knitted or nonwoven scrim.
[0010] It is an alternate object of the present invention to
provide a multilayered composite material having a continuous layer
of thermally cured unsupported polymeric foam.
[0011] It is another object of the present invention to provide a
multilayered composite material having at least one coherent layer
composed of a water-resistant blend of styrene-maleic anhydride and
acrylic resin.
[0012] It is yet another object of the present invention to provide
a multilayered composite material having a coherent layer of a
styrene-maleic anhydride and acrylic resin that impedes the
migration of monomeric and polymeric plasticizers.
[0013] It is an additional object of the present invention to
provide a multilayered composite material that does not require an
integral release coating or separable release liner to protect the
layer of coherent resin.
[0014] Finally, an object of the present invention is to provide a
multilayered composite material having a coherent anchor coating
that prevents the adhesion of residual polymeric foam to subjacent
surfaces upon removal.
SUMMARY OF THE INVENTION
[0015] The disadvantages and limitations of the background art
discussed above are overcome by the present invention. With this
invention, a removable nonslip foamed surface covering is provided,
wherein an improved multilayered composite material, having at
least one layer of resilient polymeric foam, is combined to at
least one layer of a coherent blend of styrene-maleic anhydride and
acrylic resin. In a preferred embodiment, the polymeric foam is an
expanded polyvinyl chloride (PVC) resin that is thermally cured to
a knitted or nonwoven reinforcing scrim. Alternatively, The PVC
layer may also consist of a continuous unsupported sheet of
polymeric foam. The structure of the multilayered composite
material facilitates the secured and reusable application of the
covering, even after repeated washings, to a broader range of
horizontal and vertical surfaces.
[0016] In accordance with the present invention, the primary layer
of expanded foam consists of a polymeric compound that includes: a
plasticizer; polyvinyl chloride resins; calcium carbonate; a
chemical foaming agent; a heat stabilizer; and a pigment. In a
preferred embodiment, the plasticizer may be selected from the
group of Diisononyl phthalates (DINP), Dioctyl terephthalates
(DOTP), Epoxidized Soybean Oils (ESO), or mixtures thereof. The
compound is further comprised of a copolymeric blend of two
dissimilar PVC homopolymer dispersion resins which respectively
exhibit low and medium viscosities. A calcium carbonate powder is
additionally used as filler within the polymeric formulation. The
PVC copolymeric admixture also contains a chemical blowing agent
that is selected from the group of hydrazine derivatives, and is
more particularly an Azodicarbonamide powder that is suspended in
the resin formulation. Under thermal decomposition,
Azodicarbonamide releases nitrogen when exposed to temperatures in
the range of 200.degree. to 215.degree. C., thereby causing the
expansion of the polymeric composition. To impede the heat-induced
deterioration of the compound during processing, Zinc Octoate is
used as a stabilizing additive to lower the thermal activation
range of the Azodicarbonamide powder. Finally, the PVC foam may be
colored with a pigment system that is compatible with the selection
of plasticizers used within the polymeric formulation.
[0017] The primary layer of expanded PVC foam may comprise a
thermally cured formulation that is reinforced with an intermediate
layer of knitted or nonwoven scrim. The polymeric suspension may be
applied by way of dip coating the reinforcing substrate or,
optionally, through a transfer roll coating method in which the
compound is meted out from an underlying reservoir. The coated
material is then conveyed through an oven to activate the blowing
agent and to solidify the composition. Alternatively, the polymeric
formulation may be cured by means of a thermal calendering process,
wherein the polyvinyl chloride admixture is uniformly coated on a
releasable belt or casting paper which is compressed against a
heated roller. In the absence of a knitted scrim or non-woven
substrate, the releasable belt or casting paper provides support
and dimensional stability to the unsupported polymeric compound
while maintaining the uniform thickness of the nonslip material
during solidification.
[0018] The present invention features at least one coherent layer
consisting of a water-resistant blend of Styrene-Maleic Anhydride
(SMAnh) copolymer and Acrylic resin. SMAnh is a synthetic copolymer
that is composed of almost perfectly alternating Styrene (STY) and
Maleic Anhydride (MAnh) monomers. The main characteristics of
SMAnh, which is achieved through the controlled radical
polymerization of STY and MAnh monomers, includes its transparent
appearance, high heat resistance, superior dimensional stability,
and the specific reactivity of the anhydride groups. Styrene-Maleic
Anhydride is also soluble in water-based alkaline solutions and
dispersions, and the specific reactivity of the copolymer makes it
a suitable agent for compatibilizing normally incompatible
polymers. Accordingly, the dispersion of SMAnh copolymer, blended
in combination with the suspension of Acrylic resin, functions as
an essential crosslinking agent between the coherent anchor coating
and the primary layer of PVC foam.
[0019] Further objects and advantages of the present invention will
be apparent from the following description of the preferred
embodiments when considered in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of a multilayered composite
material according to the present invention, showing a primary
layer of polymeric foam combined to a coherent layer of a
water-resistant blend of styrene-maleic anhydride and acrylic
resin;
[0021] FIG. 2 is a cross-sectional view drawn from lines 2-2 of
FIG. 1, showing the layered construction of a multilayered
composite material according to the present invention;
[0022] FIG. 3 is a cross-sectional view similar to FIG. 2 showing
the layered construction of a first alternate embodiment of a
multilayered composite material according to the present
invention;
[0023] FIG. 4 is a cross-sectional view similar to FIG. 2 showing
the layered construction of a second alternate embodiment of a
multilayered composite material according to the present
invention.
[0024] FIG. 5 is a schematic diagram of an apparatus for making the
scrim supported foamed layer of a multilayered composite material
according to the present invention;
[0025] FIG. 6 is a schematic diagram of an apparatus for making a
calendered unsupported foamed layer of a multilayered composite
material according to the present invention;
[0026] FIG. 7 is a schematic diagram of an apparatus for applying
the coherent layer of styrene-maleic anhydride and acrylic resin of
a multilayered composite material according to the present
invention;
[0027] FIG. 8 is an end view of a multilayered composite material
in rolled-up form according to the present invention; and
[0028] FIG. 9 is an end view of a third alternate embodiment of a
multilayered composite material in rolled-up form according to the
present invention.
[0029] Similar reference characters denote corresponding features
consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention is a multilayered composite material
suitable for use as a rug underlay pad or, alternatively, as a
shelf, drawer or storage liner, and generally designated as 10 in
the drawings. With reference to FIG. 1, the composite material 10
is a surface covering having a primary layer of resilient polymeric
foam 11 combined to at least one layer 12 of a coherent
water-resistant blend of styrene-maleic anhydride and acrylic
resin. The structure of the multilayered composite material 10
facilitates the secured and reusable application of the surface
covering after repeated washings.
[0031] As detailed in FIGS. 2-4, the primary layer 11 or 41
consists of an expanded polymeric foam 17, which is in the range of
1.275 mm to 6.35 mm in thickness, having appreciable and conjoint
viscous and elastic properties when deformed. In a preferred
embodiment, and as detailed by way of example in Table 1, the
expanded polymeric foam is composed of a thermally cured polyvinyl
chloride (PVC) compound that includes: a plasticizer; polyvinyl
chloride resins; calcium carbonate; a chemical foaming agent; a
heat stabilizer; and a pigment. The plasticizer may be selected
from the group of Diisononyl phthalates (DINP), Dioctyl
terephthalates (DOTP), Epoxidized Soybean Oils (ESO), or mixtures
thereof, although other plasticizers may be used. The compound is
further comprised of a copolymeric blend of two dissimilar PVC
homopolymer dispersion resins which respectively exhibit low and
medium viscosities. A calcium carbonate powder is additionally used
as filler within the polymeric formulation. The PVC copolymeric
admixture also incorporates a chemical blowing agent that is
selected from the group of hydrazine derivatives, and is more
particularly an Azodicarbonamide powder that is suspended in the
resin formulation. Alternatively, the primary layer 11 or 41 may
also be composed of other natural or synthetic resins that include
Latex; Polyurethane (PUR); Ethylene Vinyl Acetate (EVA); or other
appropriate polymeric compounds. It can be recognized that the
polymeric formula may also contain additives that are standard in
the art, including matting agents, ultra violet inhibitors,
flame-retardants, biocides, fungicides, and other ingredients.
TABLE-US-00001 TABLE 1 Compound Ingredient Parts by weight DOTP
Plasticizer 44.72% .+-. 5% PVC Resin A 23.96% .+-. 5% PVC Resin B
7.99% .+-. 5% Calcium Carbonate (CaCo3) 20.76% .+-. 5%
Azodicarbonamide 1.28% .+-. 5% Zinc Octoate 0.64% .+-. 5% Pigment
0.66% .+-. 5%
[0032] With further reference to FIGS. 2 and 3, the primary layer
of expanded PVC foam 11 may comprise a thermally cured polymeric
formulation that is reinforced with an intermediate layer of
knitted scrim 15 that may also define a series of apertures 14.
Alternatively, the intermediate reinforcing layer may consist of a
nonwoven substrate that is comprised of autogenously bonded
polyester fibers (not shown). In a preferred method, the primary
layer of supported foam 11 can be made according to the process
schematically depicted in FIG. 5. The intermediate layer of
reinforcing scrim 15 is supplied in roll form 55, and transported
under controlled tension to a transfer roll coating unit 50,
wherein the polymeric admixture is uniformly coated on the
supportive material. The polymeric compound is dispensed by
metering vat 59 by means of a supply hose 51, to a coating tray 52,
in which the transfer roller 53 is suspended. To achieve the
uniform application of the uncured compound, the transfer roller 53
delivers the polymeric dispersion to the underside of reinforcing
scrim 15, where the coated material is simultaneously compressed
against a pressure roller 54. The coated material 56 is then
conveyed through a series of ovens 57 where the material undergoes
thermal expansion and solidification. To avoid the thermal
deformation of the resultant polymeric foam structure, the
solidified material is passed through a cooling chamber 58 to lower
the temperature of the primary layer 11 before it is collected on
take up roll 111.
[0033] Turning once again to FIG. 4, the composite material 30 may
alternatively consist of an unsupported primary layer of polymeric
foam 41. The primary layer of unsupported foam 41 can be made
according to the method that is schematically illustrated in FIG.
6. The polyvinyl chloride compound 66 is cured by means of a
thermal calendering process 60, wherein the polymeric admixture is
supplied by a metering vat 69 and uniformly coated on a releasable
belt 63. The PVC compound 66 and releasable belt 63 are then
compressed under tension against a heated roller 64. As an
alternative, a releasable paper (not shown) may also be used. In
the absence of a knitted scrim or non-woven fabric, the releasable
belt 63 or casting paper functions as a carrier for the uncured
polymeric compound 66. The carrier maintains the uniform thickness
of the foam material 41 during thermal solidification. In an
alternate embodiment, the layer of unsupported polyvinyl chloride
foam 41 is in the range of 1.275 mm to 1.675 mm in thickness. The
primary layer of the PVC foam 41 may be partially solidified as the
material exits the heated roller 64, and may be further cured
through the use of heated ovens 67. The solidified layer of
polyvinyl chloride foam 41 is then cooled through contact with
cooling rollers 68, and collected on a take-up roll 411. The
uniform layer of cured PVC foam may be smooth on both sides. In a
preferred embodiment, the heated roller 64, releasable belt 63 or
casting paper is configured to impart a fine pattern of
micro-embossed indentations 42. The pattern of micro-embossed
indentations 42 are alternately spaced at 0.889 mm intervals,
although other micro-embossed configurations may also be used. The
micro-embossed indentations 42 essentially provide concaved
recesses to enhance the bonding characteristics of the coherent
layer 220 to the unsupported layer of polymeric foam 41.
[0034] As further illustrated in FIGS. 2-4, the coherent layer 12,
120a, 120b, or 220 is between 0.5 mm to 1.5 mm in thickness, and
comprises a water-resistant Styrene-Maleic Anhydride (SMAnh)
copolymer, having a glass transition (Tg) temperature in the range
of -30.degree. to -40.degree. C., which is blended with an Acrylic
resin. SMAnh is a synthetic polymer that is composed of Styrene
(STY) and Maleic Anhydride (MAnh) monomers. The copolymer is formed
by means of radical polymerization, using organic peroxide as the
initiator, although SMAnh copolymerization may be carried out via
Nitroxide Mediated Polymerization (NMP), which makes use of an
Alkoxyamine initiator. Alternatively, and as a preferred
embodiment, SMAnh copolymerization may be attained through
Reversible Addition-Fragmentation Chain Transfer (RAFT) mediated
polymerization, which uses radical initiators such as
Azobisisobutyronitrile (AIBN) or 4,4'-Azobis(4-cyanovaleric acid)
(ACVA). RAFT polymerization is known for its compatibility with a
wide range of monomers as compared to other controlled radical
polymerizations. Some monomers capable of polymerizing by RAFT
include styrenes, acrylates, acrylamides, and vinyl monomers. As
specified by way of example in Table 2, the uncured coating is
composed of: Water (H2O); Acrylic Resin; Styrene (STY); Maleic
Anhydride (MAnh); and additives. The additives contained within the
blend of SMAnh and Acrylic Resin may also include ultra violet
inhibitors, biocides, and fungicides, along with other ingredients.
It can be further appreciated that the peel strength of the
coherent layer of SMAnh and Acrylic resin should not exceed the
tensile strength of the foamed cellular structure of the primary
layer. The dispersion of SMAnh copolymer, blended in combination
with the suspension of Acrylic resin, not only functions as an
essential crosslinking agent between the coherent anchor coating
and the primary layer of PVC foam, but impedes the migration of
monomeric and polymeric plasticizers present within the
multilayered composite material.
TABLE-US-00002 TABLE 2 Compound Ingredient Parts by weight Water
(H2O) 46% .+-. 5% Acrylic Resin 40% .+-. 5% Styrene (STY) 8% .+-.
5% Maleic Anhydride (MAnh) 4% .+-. 5% Additives 2% .+-. 5%
[0035] In a similar technique used to produce the primary layer of
polymeric foam 11, the coherent layer 12, 120a, 120b, or 220 can be
applied according to the method schematically illustrated in FIG.
7. The primary layer of polymeric foam 11 or 41, is supplied in
roll form 111 or 411, and transported under controlled tension to a
transfer roll coating unit 70, wherein the blend of styrene-maleic
anhydride and acrylic resin is uniformly or discontinuously coated
on the surface covering material. The blend of coherent resin is
dispensed by metering vat 79 by means of a supply hose 71, to a
coating tray 72, in which the transfer roller 73 is suspended. To
achieve the uniform application of the uncured resin, the transfer
roller 73 delivers the dispersion of SMAnh and Acrylic resin 12 to
the underside of the primary layer of foam 11 or 41, where the
coated material is simultaneously compressed against a pressure
roller 74. The coated material 76 is then conveyed through a series
of ovens 77, where the material is thermally cured at a temperature
in the range of 87.degree. to 93.degree. C. To avoid thermal
degradation of the polymeric foam, it is imperative that the
process for thermally curing the coherent blend of SMAnh and
Acrylic resin be less than 10.degree. C. of the initial softening
point of the PVC foam, which is 148.degree. C. To further avoid
thermal deformation of the coated foam structure, the material is
passed through a cooling chamber 78 to lower the temperature of the
composite material 10, 20 or 30 before it is collected on take up
roll 100. In addition to the foregoing process, the coherent
formulation of SMAnh and Acrylic resin may be applied to the
primary layer of polymeric foam via rotary or flatbed screen
printing without departing from the scope of the invention.
[0036] In a preferred embodiment, and as shown in FIGS. 2, 4, and
8, the inherent property of the coherent layer to cling--verses
adhere--to an applied surface eliminates the need for an integral
release coating, or a separable release liner, thereby facilitating
the capacity for the foamed surface covering to be rolled upon
itself. The moderate peel strength of the coherent layer
additionally prevents the adhesion of residual polymeric foam to
subjacent surfaces upon removal. As further illustrated in FIGS. 3
and 9, the foamed surface covering may also feature two coherent
layers of SMAnh and Acrylic resin, 120a and 120b, which allows the
coated material to function as an intermediate anchor covering in a
variety of applications. Moreover, the coherent layers 120a and
120b may vary in degrees of bond strength, thereby requiring the
optional use of separable release liners 18. Finally, the
hydrophobic property of the blended Styrene-maleic Anhydride and
Acrylic resin allows the restoration of the coherent feature of the
multilayered composite material after repeated washings.
[0037] Even though numerous characteristics and advantages of the
present invention have been set forth in the foregoing description,
together with details of the structure and function of the
preferred embodiments, the above disclosure is illustrative only.
Changes may be made in detail, especially in matters of shape, size
and arrangement of parts within the principles of the invention to
the full extent indicated by the broad general meaning of the terms
in which the appended claims are expressed.
* * * * *